Sealed, self-cleaning, food dispensing system including pump and bypass passage

ABSTRACT

A sealed pressurized food dispensing system with self-cleaning features that can include a food processing apparatus that includes a cylinder having an inlet for receiving a food ingredient; a faceplate coupled to the cylinder, that defines a dispense bore and a bypass passage having a first open end; a blocking cap coupled to the faceplate to block the dispensing of product from within the cylinder; and a pump having an inlet fluidly coupled to a connection element and an outlet fluidly coupled to the inlet of the cylinder, where connection of the connection element to the source of cleaning fluid will result in the pumping of cleaning fluid into the food dispensing cylinder, though the cylinder into the blocking cap, and through the blocking cap into the bypass passage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 63/363,153 filed on Apr. 18, 2022.

BACKGROUND OF THE INVENTION

The present inventions relate to food dispensing systems and, moreparticular to sealed and/or pressurized food dispensing systems.Previously such systems have required extensive manual cleaningoperations and/or the use of complicated and cumbersome additionalattachable equipment for the required cleaning operations. The presentdisclosure sets forth methods and apparatus that overcome these andother shortcomings that exist with respect to conventional cleaningmethods and systems.

BRIEF SUMMARY OF THE INVENTION

A brief non-limiting summary of one of the many possible embodiments ofthe present invention is a sealed and/or pressurized food dispensingsystem with self-cleaning features that can take the form of aself-cleaning food dispenser, a cabinet comprising a frame structure anda plurality of panel members; a freezing cylinder located within thecabnet, the freezing cylinder having an inlet; a first evaporatorpositioned to cool the freezing cylinder; a faceplate coupled to theopen end of the freezing cylinder, the faceplate defining: a dispensebore passing generally vertically through the faceplate and a bypasspassage having a first end opening; a valve stem positioned at leastpartially within the dispense bore, the valve stem including a sealingsurface for creating a seal with a portion of the dispense bore; and avalve stem actuator coupled to the valve stem, the valve stem actuatorbeing configured to move the valve stem from a first position wheredispensing of a food product from within the freezing cylinder ispermitted to a second position where the seal between the valve stem andthe dispense bore precludes dispensing of the food product; wherein thebypass passage is positioned such that, when the valve stem is in itsfirst position, no fluid path exists between the interior of thefreezing cylinder and the first end of the bypass passage; a firstcompressor positioned within the frame structure at a location below thefreezing cylinder, the first compressor being coupled to providerefrigeration fluid to the first evaporator; a refrigerated ingredientstorage compartment, the refrigerated ingredient storage compartmentbeing positioned within the cabinet at a location below the freezingcylinder and above the first compressor; a cleaning fluid tank locatedwithin the cabinet, the cleaning fluid tank having an outlet; aself-cleaning receiver port fluidly coupled to the outlet of thecleaning fluid tank; a fluid pump located within the refrigeratedingredient storage compartment, the fluid pump having an inlet and anoutlet, the inlet of the fluid pump being fluidly coupled to a pumpconnection element that may be removably coupled to the self-cleaningreceiver port, and the outlet of the fluid pump being fluidly coupled tothe inlet of the freezing cylinder, wherein, when the pump connectionelement is removably coupled to the self-cleaning receiver port,activation of the fluid pump will result in the pumping of cleaningfluid from the cleaning fluid tank into the food dispensing cylinderwithout the use of any intervening pumping element.

Additionally, or alternately, the system can include a food processingapparatus including: a cylinder having an inlet for receiving a foodingredient; a faceplate coupled to the cylinder, the faceplate defininga dispense bore and a bypass passage having a first open end; a blockingcap coupled to the faceplate to block the dispensing of product fromwithin the cylinder; and a pump having an inlet and an outlet, the inletof pump being fluidly coupled to a connection element that may beremovably coupled to a source of cleaning fluid; wherein, when theconnection element is removably coupled to the source of cleaning fluid,activation of the pump will result in the pumping of cleaning fluid intothe food dispensing cylinder, through the cylinder into the blockingcap, and through the blocking cap into the bypass passage.

None of these brief summaries of the inventions is intended to limit orotherwise affect the scope of the appended claims, and nothing stated inthis Brief Summary of the Invention is intended as a definition of aclaim term or phrase or as a disavowal or disclaimer of claim scope.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures form part of the present specification and areincluded to demonstrate further certain aspects of the presentinvention. The invention may be better understood by reference to one ormore of these figures in combination with the detailed description ofcertain embodiments presented herein.

FIGS. 1A-1C illustrate the exterior of the exemplary dispensing systemdisclosed and taught herein.

FIGS. 2A-2D schematically illustrate various components of the exemplarydispensing system and the connections between those components.

FIGS. 3A-3E illustrate one exemplary faceplate assembly that may be usedwithin the exemplary dispenser discussed herein.

FIG. 4A illustrates an exemplary dispensing cap that may be used inconnection with the disclosed system.

FIG. 4B illustrates an exemplary blocking cap that may be used inconnection with the disclosed system.

FIG. 5A illustrates a front view of the exemplary system with a portionof the front cover and various components not associated with thedispensing sub-system hidden.

FIG. 5B illustrates a sideview of the system of FIG. 5A.

FIG. 5C illustrates an isometric view of certain components illustratedin FIG. 5A.

FIG. 5D illustrates a front view of an alternate embodiment of thedisclosed exemplary system with a portion of the front cover and variouscomponents transparent.

FIGS. 6A-6D illustrate aspects of an exemplary cylinder vent reliefassembly as used in connection with the exemplary disclosed system.

FIGS. 7A-7F illustrate aspects of an exemplary system constructed inaccordance with teachings from this disclosure, including an exemplaryingredient storage compartment and ingredient supply apparatus as usedin connection with the disclosed system with the hinged door removed.

FIGS. 8A-8E-2 illustrate details of exemplary embodiments of a pressureblock assembly as may be used with the exemplary disclosed system.

FIGS. 9A-9D illustrate an exemplary cleaner supply element as used inconnection with the exemplary disclosed system.

FIGS. 10A-10D illustrate views of exemplary components used withinrefrigeration system of the exemplary disclosed system.

FIG. 11A illustrates an exemplary primary condensate tray as used inconnection with an exemplary disclosed system.

FIG. 11B illustrates the lowest portion of the interior of the exemplarydisclosed system.

FIG. 12 illustrates a side view of the exemplary disclosed dispensingsystem.

FIG. 13A illustrates a cross section of several of the componentsillustrated in FIG. 12A.

FIG. 13B illustrates a cross-section of an exemplary temperaturecontrolled chamber with motor as used in connection with the disclosedsystem. In this example the temperature-controlled chamber is a freezing(and/or heating) chamber.

FIGS. 13C-13E-2 illustrate details concerning embodiments of anexemplary rear seal assembly that may be used in the disclosed system.

FIGS. 14A and 14B illustrates aspects of a beater bar assembly that maybe used in embodiments of system disclosed herein.

While the inventions disclosed herein are susceptible to variousmodifications and alternative forms, only a few specific embodimentshave been shown by way of example in the drawings and are described inmore detail below. The figures and detailed descriptions of theseembodiments are not intended to limit the breadth or scope of theinventive concepts or the appended claims in any manner. Rather, thefigures and detailed written descriptions are provided to illustrate theinventive concepts to a person of ordinary skill in the art and toenable such person to make and use the inventive concepts illustratedand taught by the specific embodiments.

DETAILED DESCRIPTION

The Figures described above, and the written description of specificstructures and functions below, are not presented to limit the scope ofwhat has been invented or the scope of the appended claims. Rather, theFigures and written description are provided to teach any person skilledin this art to make and use the inventions for which patent protectionis sought.

A person of skill in this art having benefit of this disclosure willunderstand that the inventions are disclosed and taught herein byreference to specific embodiments, and that these specific embodimentsare susceptible to numerous and various modifications and alternativeforms without departing from the inventions we possess. For example, andnot limitation, a person of skill in this art having benefit of thisdisclosure will understand that Figures and/or embodiments that use oneor more common structures or elements, such as a structure or an elementidentified by a common reference number, are linked together for allpurposes of supporting and enabling our inventions, and that suchindividual Figures or embodiments are not disparate disclosures. Aperson of skill in this art having benefit of this disclosureimmediately will recognize and understand the various other embodimentsof our inventions having one or more of the structures or elementsillustrated and/or described in the various linked embodiments. In otherwords, not all possible embodiments of our inventions are described orillustrated in this application, and one or more of the claims to ourinventions may not be directed to a specific, disclosed example.Nonetheless, a person of skill in this art having benefit of thisdisclosure will understand that the claims are fully supported by theentirety of this disclosure.

Those persons skilled in this art will appreciate that not all featuresof a commercial embodiment of the inventions are described or shown forthe sake of clarity and understanding. Persons of skill in this art willalso appreciate that the development of an actual commercial embodimentincorporating aspects of the present inventions will require numerousimplementation-specific decisions to achieve the developer's ultimategoal for the commercial embodiment. Such implementation-specificdecisions may include, and likely are not limited to, compliance withsystem-related, business-related, government-related, and otherconstraints, which may vary by specific implementation, location andfrom time to time. While a developer's efforts might be complex andtime-consuming in an absolute sense, such efforts would be,nevertheless, a routine undertaking for those of skill in this arthaving benefit of this disclosure.

Further, the use of a singular term, such as, but not limited to, “a,”is not intended as limiting of the number of items. Also, the use ofrelational terms, such as, but not limited to, “top,” “bottom,” “left,”“right,” “upper,” “lower,” “down,” “up,” “side,” and the like are usedin the written description for clarity in specific reference to theFigures and are not intended to limit the scope of the invention or thescope of what is claimed.

Reference throughout this disclosure to “one embodiment,” “anembodiment,” “an example” or similar language means that a particularfeature, structure, or characteristic described in connection with theembodiment is included in at least one of the many possible embodimentsof the present inventions. The terms “including,” “comprising,”“having,” and variations thereof mean “including but not limited to”unless expressly specified otherwise. An enumerated listing of itemsdoes not imply that any or all of the items are mutually exclusiveand/or mutually inclusive, unless expressly specified otherwise. Theterms “a,” “an,” and “the” also refer to “one or more” unless expresslyspecified otherwise.

Furthermore, the described features, structures, or characteristics ofone embodiment may be combined in any suitable manner in one or moreother embodiments. In the following description, numerous specificdetails are provided, such as examples of programming, software modules,user selections, network transactions, database queries, databasestructures, hardware modules, hardware circuits, hardware chips, etc.,to provide a thorough understanding of embodiments of the disclosure.Those of skill in the art having the benefit of this disclosure willunderstand that the inventions may be practiced without one or more ofthe specific details, or with other methods, components, materials, andso forth. In other instances, well-known structures, materials, oroperations are not shown or described in detail to avoid obscuringaspects of the disclosure.

Aspects of the present disclosure are described below with reference toschematic flowchart diagrams and/or schematic block diagrams of methods,apparatuses, systems, and computer program products according toembodiments of the disclosure. It will be understood by those of skillin the art that each block of the schematic flowchart diagrams and/orschematic block diagrams, and combinations of blocks in the schematicflowchart diagrams and/or schematic block diagrams, may be implementedby computer program instructions. Such computer program instructions maybe provided to a processor of a general-purpose computer, specialpurpose computer, or other programmable data processing apparatus tocreate a machine or device, such that the instructions, which executevia the processor of the computer or other programmable data processingapparatus, structurally configured to implement the functions/actsspecified in the schematic flowchart diagrams and/or schematic blockdiagrams block or blocks. These computer program instructions also maybe stored in a computer readable storage medium that can direct acomputer, other programmable data processing apparatus, or other devicesto function in a particular manner, such that the instructions stored inthe computer readable storage medium produce an article of manufactureincluding instructions which implement the function/act specified in theschematic flowchart diagrams and/or schematic block diagrams block orblocks. The computer program instructions also may be loaded onto acomputer, other programmable data processing apparatus, or other devicesto cause a series of operational steps to be performed on the computer,other programmable apparatus or other devices to produce a computerimplemented process such that the instructions that execute on thecomputer or other programmable apparatus provide processes forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks.

The schematic flowchart diagrams and/or schematic block diagrams in theFigures illustrate the architecture, functionality, and/or operation ofpossible apparatuses, systems, methods, and computer program productsaccording to various embodiments of the present inventions. In thisregard, each block in the schematic flowchart diagrams and/or schematicblock diagrams may represent a module, segment, or portion of code,which comprises one or more executable instructions for implementing thespecified logical function(s).

It also should be noted that, in some possible embodiments, thefunctions noted in the block may occur out of the order noted in thefigures. For example, two blocks shown in succession may, in fact, beexecuted substantially concurrently, or the blocks may sometimes beexecuted in the reverse order, depending upon the functionalityinvolved. Other steps and methods may be conceived that are equivalentin function, logic, or effect to one or more blocks, or portionsthereof, of the illustrated figures.

Although various arrow types and line types may be employed in theflowchart and/or block diagrams, they do not limit the scope of thecorresponding embodiments. Indeed, some arrows or other connectors maybe used to indicate only the logical flow of the depicted embodiment.For example, but not limitation, an arrow may indicate a waiting ormonitoring period of unspecified duration between enumerated steps ofthe depicted embodiment. It will also be noted that each block of theblock diagrams and/or flowchart diagrams, and combinations of blocks inthe block diagrams and/or flowchart diagrams, may be implemented byspecial purpose hardware-based systems that perform the specifiedfunctions or acts, or combinations of special purpose hardware andcomputer instructions.

The description of elements in each Figure may refer to elements ofproceeding Figures. Like numbers refer to like elements in all figures,including alternate embodiments of like elements. In some possibleembodiments, the functions/actions/structures noted in the figures mayoccur out of the order noted in the block diagrams and/or operationalillustrations. For example, two operations shown as occurring insuccession, in fact, may be executed substantially concurrently or theoperations may be executed in the reverse order, depending upon thefunctionality/acts/structure involved.

The embodiments of the exemplary system disclosed and discussed hereintakes the form of a system that includes a temperature controlledcylinder (e.g., in the form of a freezing barrel) for dispensing heated,chilled, near-frozen, ambient temperature, and/or frozen food items. Itshould be understood, however, that the reference to such a food item isexemplary only and that the disclosed system may be used for dispensingfood items of varying temperatures and/or consistencies. In one of manyexamples, the exemplary component described herein as a freezingcylinder could be operated as, or replaced with, a heating containersuch that the described dispenser may be used to dispense a heated fooditem (such as a hot beverage or soup). Alternatively, that describedcomponent could, in suitable circumstances, be used to dispense fooditems at ambient temperatures. As such all specific references herein toa “freezing” cylinder (or freezing barrel) are exemplary only and itwill be understood that, in alternate embodiments, the “freezing”cylinder could be replaced with any temperature-controlled cylinder and,in still further embodiments, in some instances, with a cylinder inwhich the temperature is not directly controlled but is allowed to tendtowards ambient temperature levels.

It should also be understood that the following example focuses on adispensing system that includes a single freezing cylinder. This isexemplary only and the concepts, ideas, and teachings of this disclosurecan readily be expanded to systems that include multiple cylindersand/or where the container from which the food item is dispensed takesthe form of something other than a cylinder, such as a storage containerhaving a cross section other than circular.

Turning to the drawings and, in particular, to FIGS. 1A-1C, anillustrative exemplary embodiment of a compact, highly controllable,variable-product, sealed, self-cleaning pressurized food dispensingsystem 1000 is depicted.

In the illustrated example, the overall food dispensing system 1000comprises various sub-systems, with each comprising one or morecomponents that are contained within and/or attached to a framestructure formed from a plurality of base frame elements and a pluralityof structural panels coupled to the frame elements.

In the example of FIGS. 1A-1C, the overall system is coupled to fourcaster assemblies 1005 (two of which are lockable) to facilitatemovement and positioning of the illustrated dispensing system. Alternateembodiments are envisioned where legs or other support structures may beused in place of casters and where the system structure rests directlyon a floor, a work surface, a tabletop, or other stable base structure.

As reflected in the figures, the front portion of the dispensing system1000 includes a lower front kick plate 1010 that defines a plurality ofopenings in the form of substantially horizontal vents 1015, each ofwhich extends across the majority of the surface of the kick plate 1010.The purpose of the vents in the kick plate is to permit air to pass fromthe exterior of the system to the interior of the system, or in somecircumstances in the opposite direction.

The front portion of the dispensing system also includes a refrigeratordoor 1020 that, as discussed in more detail below, may be opened toaccess a refrigerated product storage compartment positioned within theinterior of the system. In the example of FIGS. 1A-1C, the refrigeratordoor 1020 is formed of an insulated door that is adapted to be connectedto hinges, such that the door may be opened and closed to access therefrigerated storage compartment within the system.

As reflected in FIGS. 1A-1B, the refrigerator door 1020 may be locatedabove the kick plate 1010 and below a dispenser system 1030 (discussedbelow). In the illustrated example of FIGS. 1A-1C, a drip tray 1025 maybe connected to the refrigerator door 1020 and moves with therefrigerator door 1020 when it is open and/or closed. It will beappreciated that the specific location of the drip tray 1025 in FIGS.1A-1C is exemplary only and that the drip tray can be positioned atalternate locations without departing from the teachings of thisdisclosure. For example, alternate embodiments are envisioned whereinthe drip tray is positioned and connected above the kick plate and belowthe door, such that the drip tray remains static while the refrigerationdoor opens and closes.

As best shown in FIG. 1A, the exemplary dispenser system 1000 includes adispensing faceplate (unlabeled in FIG. 1A-1C) and a cold pack coverpanel 1035, both of which may be located above the refrigerator door1020. In the illustrated example, a user interface in the form of apush-button dispensing switch 1040 is positioned within the cold packcover panel 1035 which (as discussed in more detail below) may be usedto dispense product from the system.

It will be appreciated that the use of a push-button dispensing switchto control the dispensing of product from the system is exemplary onlyand that other apparatus and systems known to those skilled in the artmay be used to control the dispense operation. For example, alternativeembodiments are discussed below in which a lever is manipulated todispense product from the system 1000.

Referring back to FIG. 1A, a top front cover panel 1045 may be locatedabove the cold pack cover panel 1035 and an electronic display 1050 maybe positioned within top front cover panel 1045. The electronic displaymay be used to configure and control aspects of the system 1000, toprovide diagnostic and operating information about the system, and/or todisplay images and communications of interest during the normaloperation of the system (e.g., information about the product to bedispensed by the system or promotional information about items offeredat the location in which the system 1000 is located).

The rear of the illustrative system is generally shown in FIG. 1B. Asreflected in the figure, the rear of the illustrated system comprises arear panel 1055 that defines a number of substantially horizontal vents1060 that extend across approximately the lower ⅔ the rear panel and asubstantially unvented portion of the panel that extends acrossapproximately the upper ⅓ of the rear panel. The purpose of the vents inthe rear panel is to permit air to pass from the interior of the systemto the exterior of the system, or in some circumstances in the oppositedirection. It will be appreciated that the depiction of horizontal ventsis exemplary only and that vents having alternate forms and orientationsbe used without departing from the teaching of the present disclosure.For example, the vents need not take the form of slits and could,alternately, take the form of circular or other-shaped openings.Further, the vents need not be arranged horizontally and could, inalternative embodiments, be arranged vertically, on a slant, or in anyother orientation. In the illustrate embodiment of FIG. 1B connectionpoints are provided at the lower rear of the unit for connecting thedisclosed system to a drain through drain connection 1806, to a sourceof water through water supply connector 1802, and (optionally) to anexternal source of pressurized gas or air through optional gas connector1804. It will be appreciated that the illustrated location andarraignment of the described connectors in exemplary only and that theylocation and arrangement of such connectors can be changed withoutdeparting from the teachings of this disclosure.

As reflected in FIG. 1A, this embodiment of the exemplary system 1000has a top of the system that comprises a solid top panel 1062 that doesnot include a hopper cover or any removable structure for the additionof products or ingredients to the system. In envisioned embodiments,this top surface may be load-bearing so that a display may be mounted orattached.

As also reflected in FIG. 1A, the exemplary illustrated system mayinclude a first side panel 1065 that is substantially solid except foropenings for connecting components (e.g., screws, rivets or bolts) andan opening within which may be positioned a power and/or motordisconnect switch 1070. In the specific example of FIG. 1A, the motordisconnect switch 1070 takes the form of an all pole disconnect switchthat can be used to switch all power off to the system. It will beappreciated, however that the use of an all pole disconnect switch isexemplary only and that, in certain applications, alternate switches anddisconnects could be used, (such as, for example, a disconnect switchthat switches power off to one, or a subset of components within thesystem, such as a motor). The specific form of any disconnect switch mayvary depending on user preference, intended application, and/orapplicable product safety standards.

As reflected in FIG. 1C, the exemplary system includes a second sidepanel 1080 that, like the first side panel, is substantially solidexcept for openings for connecting components (e.g., screws, rivets orbolts) and an opening 1085 in a portion of the upper ⅓ of the secondside panel. As described in more detail below, the opening 1085 isassociated with a rear seal drip tray and may be useful for providing avisual indication of aspects of the interior of the system 1000 duringoperation of the system. It could be appreciated that the location ofthe drip tray shown in FIG. 1C is exemplary only and that the drip traycould be positioned in a different location without departing from thescope of the present disclosure. For example, in alternate embodiments,the drip tray could be located such that it opens into panels other thanpanel 1080.

Of note, in the illustrated example, there are no air vents located ineither the first side panel or the second side panel and the majority ofthe first and second side panels are solid. This construction ispermitted by the fact that in the illustrated example, the primaryairflow paths through the system are from the back of the system,through the rear panel 1055, through the interior of the system, and outof the front of the system—through the vents in the kick plate 1010.This back-to-front airflow may be advantageous because it permits theillustrated system to be positioned closely adjacent, in a side-by-sidemanner, with other dispensing systems of a similar design and/or othersystems or structures without materially impacting the operation of thesystem. While the exemplary system 1000 is described herein with theairflow from the back-to-front, the disclosures and teachings herein maybe used by those sufficiently skilled in the art to envision a systemwith the airflow from the front to the back, from one side to the other,from top-to-bottom (or vice versa) or in other directions, withoutdeparting from the inventions disclosed herein.

Given the desirability of arranging a number of frozen productdispensers side-by-side (e.g., in a location where different dispensersdispense different flavors of soft-serve ice cream) this ability toarrange a plurality of systems in close proximity with each other, on aside-by-side basis may be of significant commercial vale.

As will be appreciated from FIGS. 1A-1C, a further significant advantageof the illustrated system is that all components of the system may beconfigured and arranged to fit within a very compact footprint. In theillustrated embodiment, for example, the components of the illustratedsystem have been selected and arranged so that the overall system canfit within a space no larger than 33.5 inches in depth, 65.5 inches inheight and 20 inches in width. This compact footprint is of significantcommercial value in that it enables the use of a single dispensingsystem in a tightly confined space and/or the use of a plurality ofdispensing systems within a given space than would be permitted ifconventionally sized frozen food dispensers were utilized.

In general, the exemplary system 1000 described above may be operated inat least three different operating states: (a) a product formation anddispense state; (b) a self-cleaning state; and (c) a lock-out state.

In a first operating state, in which food product may be formed anddispensed, the system 1000 processes one or more provided foodingredients to produce a product having certain target characteristics(e.g., a soft-serve ice cream product, a shake or a smoothie producthaving a desired consistency, etc.). When operating in this state, thesystem 1000 may be provided with one or more food ingredients. In oneembodiment, the food ingredient may be in the form of a liquidingredient contained in a sterile or substantially sterile bag containerthat includes a connecting port. These ingredient containers may bepositioned within a product compartment within the system where they maybe maintained at a temperature intended to maintain the freshness of theproduct and to avoid undesirable bacteriological growth. One exemplaryembodiment of such a compartment may be a refrigeration compartment, butas disclosed elsewhere within this disclosure, it may be a heatingcompartment or a compartment to maintain any other temperature orenvironmental condition such, but not limited to pressure and humidity.In alternate embodiments, the food ingredient (or ingredients) may beprovided in a sanitary (but not sterile) container. In still a furtherembodiment, the system can be adaptable to accept one or more foodingredients in either a sterile or a sanitary form. In such embodiments,the system can further be configured to automatically detect, e.g.,through the use of a scanner or a sensor that will detect an indiciaassociated with the food ingredient supply container, the nature of theprovided ingredient. In alternate embodiments, the system can include ascanner that can be used by a user to scan an indicial that providesinformation about each provided food ingredient. In still otherembodiments, the user can manually enter information about each providedfood ingredient and/or use an automatic detection device and/or ascanner to provide the system with such information. In suchembodiments, the system can use the provided information to determinerecommended and/or mandatory cleaning intervals for the system and/orproduct expiration. In embodiments where multiple food ingredients areused in the system, the shortest recommended/mandatory cleaningintervals and the shortest product expiration intervals can be selectedby the system. In such embodiments, the system can use the electronicdisplay, sounds, a notice light and/or other communications (such as atext message, an e-mail message, etc.) to notify a user that arecommended or mandatory cleaning interval has arrived or isapproaching) and/or that a recommended or mandatory product expirationinterval has occurred or is approaching. In still further embodiments,the system can be configured to lock out all dispense or productcreation operations upon the expiration of a cleaning or productexpiration interval without the detection of a cleaning operation or aproduct replacement.

Within the refrigeration compartment, the bag containers may be coupledthrough the connecting port to a product conveyance system that, amongpotentially many other things, pumps the liquid food ingredient from thebag container to a mixing reservoir. The conveyance system mayoptionally mix the liquid food product in the mixing reservoir with oneor more pressurized gases. Similarly, the conveyance system mayoptionally mix the liquid food product (with or without the added gas orgases) with water or another liquid. With or without any additions, theconveyance system may pump the liquid food product into a productformation chamber which, in the illustrated example, may take the formof a freezing cylinder.

The system may then control the temperature within the freezing cylinderchamber and the operating characteristics of a scraper, an auger and/ora scraper/auger assembly to convert the liquid food product pumped fromthe bag container into a food product having a desired consistency. Forexample, if the food ingredient in the bag is intended to be used toprepare a product that can be dispensed as soft-serve ice cream, thesystem may control the components of the freezing/cooling chamber toproduce a product having the desired characteristics for soft-serve icecream. Alternatively, if the desired dispensed product is a shake or asmoothie, the disclosed system may control the operation of thefreezing/cooling system to produce a product having the desiredconsistency for such products. Still further, the system may adjust thetemperature within the freezing cylinder in such a manner that anyfrozen product within the cylinder is melted (or liquified) and thenrefrozen and/or reconstituted. The ability of the present system toliquify and reconstitute the product in the cylinder permits control andmaintenance of key product characteristics, such as consistency, feel inthe mouth, texture, etc. Given the high degree of controllabilitypermitted by the present system, the consistency and nature of thedispensed products are not limited to soft-serve, shakes and smoothiesand may span a range from a highly viscous dispensed product, to aproduct having a consistency of thick-packed soft-serve, to a producthaving a water-like consistency and/or most any consistency in between.

During a second operating state, the disclosed system may provide aself-cleaning feature where the components within the system 1000 thatcome into contact with the ingredients used to form the dispensedproduct and/or any dispensed or intermediate forms of the food productare cleaned and sanitized without any significant operator involvement(other than to potentially add cleaning solutions and/or initiate thecleaning process). In addition, in the illustrated embodiment, thedisclosed system cleans and sanitizes components within theself-cleaning circuit, in addition to providing an ability to self-cleanthe system components that come into contact with ingredients and/orproducts (sometimes referred to as the product circuit). This ability toself-clean, and to self-clean both components within the product circuitand the self-cleaning circuit, is one of many important aspects ofcertain embodiments of the present system.

During a third operating state, the system may be placed in a lock-outstate where no product can be dispensed until certain other actions areperformed and/or certain system checks are made. As discussed below,this lock-out state may be useful in ensuring efficient and properoperation of the system.

The disclosed exemplary system varies from other systems for foodpreparation and dispensing systems in many ways. Those ordinarilyskilled in the art and in possession of the disclosures and teachingscontained herein may see at least the following exemplary differences:the system may be capable of processing a wide-variety of products; maybe capable of processing each of the various products to reach one ormore desired product states (where each product state is associated withan aggregate of product characteristics, such as consistency, density,overrun, etc.); may be capable of automatically promoting safe andefficient operation of the system; and may be capable of providingself-cleaning (or clean-in-place) functionality. The general structureof the exemplary disclosed system and its various modes of operation maybe better understood through consideration of FIGS. 2A-2C whichschematically provide a piping and instrumentation diagram of thepneumatic and fluid systems within the overall exemplary dispensingsystem.

It should be understood that FIG. 2A illustrates various componentsthat, in an implemented system, may be dynamically controlled by asystem controller. While FIG. 2A does not specifically illustrate theconnections between the various controlled devices and the systemcontrol system, it should be understood that such connections, and thoseenvisioned by those ordinarily skilled in the art, may exist in anyimplemented system. In the same sense, FIG. 2A illustrates varioussensing devices that provide output signals that reflect variousoperating conditions of the system. It may be understood that, while theconnections between such sensing devices and the system control systemare not shown, such connections may exist in any exemplary implementedsystem. Furthermore, while a specific system control system is notillustrated in FIG. 2A, it may be understood that such a control systemmay take the form of any suitable control system and, in one of manyexemplary embodiments, could take the form of a dedicated programmablelogic controller (without any interfaces necessary to provide theappropriate control signals or receive any appropriated sense signals),a custom control board, or a distributed control system in which thecontrol logic is implemented in control modules positioned throughoutthe system.

At a high level, the connections and components depicted in FIG. 2A maybe divided into three general groups: a first group of connections andcomponents associated with the treatment, storage and distribution ofone or more gases (e.g., compressed atmospheric air); a second group ofconnections and components associated with the preparation anddispensing of a food product; and a third group of piping and componentsassociated with self-cleaning and self-sanitizing features. Each ofthese groups will be separately discussed.

Referring to FIG. 2A, certain piping and components associated with anexemplary system involving the treatment, storage and distribution ofone or more pressurized gases is illustrated. In general, the exemplarysystem may use one or more pressurized gases to both: (a) operatevarious pneumatic components of the system and (b) inject gas into theproduct freezing chamber. In the exemplary embodiment of FIG. 2A, thepneumatic system uses a single pressurized gas in the form of compressedatmospheric air generated within the system through the use of anon-board compressor for both purposes. In other embodiments, atmosphericor other gases may be used from an external source such as a gascylinder.

As reflected in FIG. 2A, an air pump/compressor 2002, which ispreferably in the form of an oil-free pump, may be provided that iscapable of pumping air from outside the illustrated pneumatic systeminto the system. In the illustrated system, the air pumped by air pump2002 is passed through a dryer 2004 and a filter 2006 (through one ormore check valves, illustrated) into an air accumulator 2008 which maytake the form of an air tank. In the illustrated embodiment, the airaccumulator 2008 may take the form of a polypropylene tank having acapacity of approximately 35 cubic inches, with a nonreactive material,such as but not limited to polypropylene, being selected to avoid theformation of rust or corrosion.

A first pressure transducer 2010 may be provided to monitor the pressureat the output of the accumulator 2010 and the output of the firstpressure transducer 2010 can be provided to an overall system controlleror a dedicated controller to control the operation of the air pump 2002so that the air pressure within the accumulator 2008 is maintainedwithin a desired range. In the exemplary embodiment, the pump 2002 andthe first pressure transducer 2010 operate to maintain the pressurewithin the accumulator 2008 within a given desired range. In oneembodiment, the pump 2002 and first pressure transducer 2010 may be usedto maintain the pressure within the accumulator 2008 such that it isalways equal to or above approximately 60 PSI and equal to or belowapproximately 90 PSI.

As shown in FIG. 2A, the output of the accumulator 2008 is also appliedto the input of a pressure regulation device 2012. The pressureregulation device 2012 is used to provide at its output a source ofpressurized air that is maintained at a relatively stable air pressure.In one exemplary embodiment, the output pressure from the regulationdevice 2012 is set such that it is approximately 60 PSI. A secondpressure transducer 2014 may be used to monitor the output of thepressure regulator 2012 to ensure that the pressure regulator and thepneumatic system is operating properly.

In the illustrated exemplary system, the pressurized air available atthe output of the pressure regulator 2012 is provided to a number ofelectrically controlled solenoid valves that can be actuated to providepressurized air to other components of the system. In the exemplaryexample, the pressurized air may be provided to four electricallycontrolled valves, each of which is separately discussed below.

As shown in FIG. 2A the regulated pressurized gas available at theoutput of the pressure regulator 2012 is provided to a firstelectronically controlled three-way solenoid valve 2016 that, whenactuated, will pass the regulated pressurized gas through the valve 2016and eventually through a check-valve 2018 into a junction point where(as described below) the provided gas can mix with fluids pumped througha pump 2300 at a mixing junction point or passage 2400. As shown in FIG.2A, a pressure transducer 2402 may be used to provide a signalindicative of the pressure at the mixing junction point or passage 2400.

As reflected in FIG. 2A, the gas flowing through the first valve 2016can optionally flow through a flow control orifice device 2020 and ahigh purity air filter 2022 before flowing into and through the aircheck valve 2018. As described in more detail below, the pressurized gasflowing through the check valve 2018 can be used by the system, amongother things, to inject a gas into the ingredients provided to thefreezing cylinder 2500 to affect the characteristics of the product tobe dispensed from the system and/or introduce gas into fluidscirculating through the system for cleaning and/or sterilizationpurposes. For example, in certain cleaning operations, the check valve2018 (or an additional check valve fed from a different gas supply line)may be used to provide ozone gas, or any other suitable sanitizingfluid, for use in sanitizing the components of the illustrateddispensing system.

As discussed above in connection with FIGS. 1A-1B, the exemplaryembodiment under discussion, includes a refrigerated ingredient storagecompartment in which ingredients used to form the dispensed food productmay be stored. In the FIG. 2A, the dashed box 2600 is intended toreflect the physical boundaries of the ingredient refrigerationcompartment, discussed in more detail blow. Thus, as shown in FIG. 2A inthe illustrated embodiment, the pressurized gas line from the air valve2016 penetrates the refrigeration compartment such that the mixingjunction at which the provided pressurized gas mixes with the ingredientline to the freezing cylinder 2500 is located within the refrigerationcompartment.

As further reflected in FIG. 2A the pressurized gas from the regulator2012 is also provided to second electrically controlled solenoid valve2026 that is used to control the application of pressurized gas to apneumatic line that, in turn, is used to control a freeze cylindervent-relief valve or valve assembly 2028. Valve 2026 may take the formof a three-way valve, such that the pressure in the pneumatic line isvented to ambient pressure when the control solenoid is off. Asdiscussed in more detail below, the freeze cylinder vent element 2028 isan element that can be activated (through activation of the secondelectrically controlled solenoid valve 2026) to provide a path throughwhich gases (and, potentially fluids) can be discharged from thefreezing cylinder 2500 to reduce the pressure within the freezingcylinder.

As further reflected in FIG. 2A in the exemplary embodiment, thepressurized gas from the regulator 2012 may also be provided to a thirdelectrically controlled solenoid valve 2030, that may take the form of athree-way valve. As discussed in more detail below, valve 2030 may beused to control the application of pressurized gas to a dispenseassembly 2032 (discussed in more detail below) that can be activated todispense food product from the freezing cylinder 2500. Note that whenthe valve 2030 is a three-way valve, the pressure in the pneumatic linecoupled to the dispense assembly 2032 may be vented to ambient pressurewhen the control solenoid is off.

As still further reflected in FIG. 2A in the illustrated embodiment, thepressurized gas from the regulator 2012 is also applied to fourthelectrically controlled solenoid valve 2034 that controls theapplication of pressurized gas to an air check valve 2037 and to ajunction point 2038 where the provided gas mixes with the output from avent flush valve 2208 (discussed in more detail below).

As discussed in more detail below, the valve 2034 can be operated toperform a variety of different functions. Among them, the valve 2034 maybe activated to supply pressurized gas to a cylinder vent reliefassembly flush passage 2036 (and vent relief valve 2028) within thedispensing unit face plate (discussed below) so that it can be entrainedinto a fluid supply line used during a self-clean operation to clean thecylinder vent relief assembly flush passage 2036 (and vent reliefassembly 2028). In addition, the valve 2034 may be activatedsimultaneous with one or more of the other valves 2016, 2026, and/or2030 to adjust the instantaneous pressure in the pneumatic line coupledto the input lines for valves 2016, 2026, and/or 2030 so as to controlthe amount of gas passed through the other valves during the periods ofsimultaneous activation. Thus, for example, simultaneous activation ofthe valve 2034 with the valve 2016, may be used to adjust and controlthe amount of pressurized gas provided to the mixing junction 2400(discussed above). Note further that the valve 2034 may be activatedprior to or after activation of valve 2016, that the valves 2034 and2016 may be activated alternatively, or in alternating intervals ofsimultaneous activation and singular activation, to control the same.

In the example described above, each of the three-way solenoid valves2016, 2026, 2030 and 2034 is an electrically actuated normally closedvalve that may be activated by the provision of a 24V signal to thecontrol line for each valve. As noted above, these solenoids may bedirectly controlled by the outputs of a controller or by outputs from anintermediate signal board that converts signals from a controller intosignals capable of controlling the state of the solenoid valves.

As will be appreciated by those skilled in the art and in possession ofthe disclosures and teachings of this disclosure, in the example of FIG.2A, the compressed atmospheric air available in the accumulator 2008provides the sole source of pressurized gas. This pressurized gas may beused for a variety of purposes including, but not limited to: (a)providing a source of gas to be combined with an ingredient feed lineprior to the ingredient being fed into the freeze cylinder; (b)actuating various pneumatically actuated components in the system (e.g.,vent relief assembly 2028 and the dispense assembly 2032); and (c)purging various lines or providing a source of gas for aeration.Alternate embodiments are envisioned, however, in which the systemutilizes alternative sources of gas. For example, alternativeembodiments are envisioned where there is no on-board air compressionsystem and pressurized gas is supplied from an external source to theregulator 2012. Still further alternative embodiments are envisionedwhere a source of regulated gas is provided at a point corresponding tothe output of regulator 2012 and there is no regulator within thesystem.

Still further alternative embodiments are envisioned wherein the gasused to combine with the product feed line into the freeze cylinder isdifferent from the gas used in other portions of the pneumatic system.Such alternate embodiments are of potential benefit in systems wherespecialized gases are desired to be used for product formation and/orwhere compressed atmospheric air may be unsuitable.

For example, alternative embodiments are envisioned where the gas inputline coupled to the solenoid valve 2016 is provided at the output of agas manifold that, in turn, is coupled to two or more different gassources. The three different gas sources may comprise three containersof the same compressed gas (e.g., an oxygen mix) or three containers ofdifferent gases (e.g., a sanitizing and/or cleaning gas composition,nitrogen, and/or carbon dioxide). Control elements in the manifold couldbe used to direct different gases to the solenoid valve 2016 and, thisin turn, into the line feeding the cylinder and, thus, into and throughvarious components in the system.

Thus, for example, if the product to be dispensed is intended to be afrozen coffee product, the manifold may be operated to provide nitrogeninto the product feed line. Similarly, nitrogen may be used inapplications where the dispensed product will be a nutraceutical productor a food product used to feed hospital patients or individuals withvarious compromised immune systems since the growth rate of microbes ina sterile, nitrogen rich environment will typically be less than thegrowth rate of microbes in an atmospheric environment.

Alternatively, if the product to be dispensed is intended to be a frozencarbonated product, then the manifold may be operated to provide carbondioxide to the feedline.

Still further, if the provided gas is a sanitizing and/or cleaning gas,the gas may be introduced into the system as part of a self-cleaningoperation to assist in the sanitization and/or cleaning of the overalldispending system.

As described above, the exemplary dispensing system may be operated invarious modes including a product formation and dispensing mode and aself-cleaning mode. In the exemplary system, the configuration of thesystem—and in particular some of the piping connections—may vary betweensome or all of the different modes. This piping configuration may beadjusted in several ways including, for example, through userinteraction with the system.

In the described example, the illustrated system includes a fluid inputconnector 2610 (designated generally in FIG. 2A) that may be coupled toeither: (a) an outlet port from an ingredient supply source (designatedgenerally as 2700 in FIG. 2A) when the system is intended to be in theproduct formation and dispense mode or (b) a self-cleaning receiver port2800 (discussed in more detail below) when the system is intended to beoperated in the self-cleaning mode.

In addition, the illustrated system includes a system bypass passage2900 that is either: (a) disabled (such that it is NOT within the flowpath of material dispensed from the freezing cylinder 2500) when thesystem is to be operated in the product formation and dispense mode; or(b) enabled (such that material dispensed from the freezing cylinderwill flow into the bypass passage 2900 when the system is to be operatedin a self-cleaning mode).

FIG. 2B illustrates the configuration of the illustrated system when thesystem is intended to operate in the product formation and dispensemode. As noted above, in this configuration, the system fluid inputconnector 2610 is coupled to an ingredient supply element 2700 and thesystem bypass passage 2900 is NOT within the flow of the system (e.g.,it is not enabled).

Referring to FIG. 2B, it will be seen that in the illustratedconfiguration the output from the ingredient supply element 2700 iscoupled to the input of a fluid pump 2300. As such, operation of thepump 2300 will cause ingredient to be pulled from the ingredient supplyelement 2700 into the line connecting the pump 2300 with the freezingcylinder 2500.

The pump 2300 may take the form of a suitable pump and it may beactuated electrically or pneumatically. In the example under discussion,the pump 2300 may take the form of a positive displacement pump, or forexample a peristaltic pump. In some embodiments, a check valve 2302 maybe provided in the line between the pump 2300 and the freezing cylinder2500 to prevent any backflow of material into the pump. It will beappreciated that when the pump 2300 takes the form of a peristalticpump, a check valve 2302 may not be required to prevent backflow, butcould be optionally included.

As shown FIG. 2A, sensors may be placed at the input of and the outputof the pump 2300 to provide information to the control system concerningthe operation of the pump and/or the extent of ingredients beingsupplied to the freezing cylinder 2500. In the example, of FIG. 2B thesensor 2402 takes the form of a pressure transducer. In the example ofFIG. 2B the sensor 2306 may also be a pressure transducer, although itwill be understood that other forms of sensors, such as a flow sensorthat would detect flow through the line between the system input port2610 and the pump 2300, or a volume sensor that would detect the volumeof such flow, could be used instead of or in addition to a pressuresensor.

In general, during the mode of operation reflected in FIG. 2B, operationof the pump 2300 will pull ingredients from the ingredient supply source2700 through the pump 2300 (and the optional check valve 2302) to thejunction point or passage 2400. At that point, through operation of theair valve 2016, pressurized gas (or air) can be injected into the systemat the junction point or passage 2400 to inject air into the ingredientsupply line feeding the freezing cylinder 2500.

The unique arrangement of the components in the illustrated systemallows for the dynamic control of the overrun of the ingredient materialprovided to the freezing cylinder which, in turn, allows the illustrateddispensing system to dynamically control one or more characteristics ofthe dispensed food item. It also allows, for example, an arrangementthat permits purging of the system of product. Such purging can beuseful, for example, during a draining process.

One characteristic of the dispensed food item that may be dynamicallycontrolled through use of the present system is overrun.

In general, with respect to a dispensed food product—and in particular adispensed frozen food product such as soft-serve ice cream—overrunrefers to the extent of the dispensed product that comprises air (oranother gas) incorporated into the dispensed product. In some instances,overrun is defined as a percentage number where the percentage refers tothe percentage of expansion of the product resulting from theincorporation of air (or another gas) into the product. Thus, forexample, if 1 gallon of liquid ingredient is combined with air (oranother gas) to produce 1.3 gallons of dispensed product, the overrun insuch an example would be 30%.

In the illustrated embodiment, the extent of overrun for the dispensedproduct may be controlled by controlling the operation of the solenoidvalve 2016, which controls the amount of air fed to the ingredientoutput line from the ingredient pump 2300. For example, in oneembodiment the solenoid valve 2016 could be controlled to operate inaccordance with a pulse width modulation control strategy where pulsesof air are applied at a determined period (e.g., approximately 300milliseconds) and the width of the pulses is controlled from a minimumpulse width of 0% of the available pulse period to 100% of the availablepulse period. In alternate embodiments, a pulse frequency modulationapproach could be used where constant width pulses are applied atdiffering frequencies to control the amount of air (or other gas)provided to the output of the ingredient pump.

Still further embodiments are envisioned wherein the valve 2016 is adynamically adjustable valve that can—for example—be controlled to openan area of a passage within the valve such that operation of the valve2016 can control the extent of the air (or other gas) provided to thejunction point or passage 2400. Still further embodiments are envisionedwhere a form of metering pump may be used to control the amount of air(or other gas) provided for incorporation into the dispensed product.

As will be appreciated through the use of the dynamic overrun controlcomponents discussed above, the overrun of the dispensed product may becontrolled and tailored to produce a desired output product for a giveningredient set and/or to adjust the extent of the overrun to accommodatedifferent products. For example, embodiments are envisioned whereindicia on a product ingredient bag will contain an indication of theoptimum overrun for that ingredient. In such embodiments, a user oroperator of the described system can—upon the coupling of a giveningredient supply unit to the system—compare the system overrun settingswith the pertinent optimum overrun setting and adjust the overrunsetting to the optimum setting. Such an adjustment can, for example, beaccomplished through the use of a touch screen interface (or any otherinterface known to those skilled in the art, which may include awirelessly connected interface). In one envisioned embodiment, thesystem may be provided with an interactive display screen (e.g., a touchscreen display and the overrun adjustment can be accomplished throughthe user or operator interfacing with the display, for example byadjusting a slider bar that sets the overrun amount.

Still further embodiments are envisioned wherein each ingredient supplyunit includes a machine-readable code (e.g., a QR code) that isscanned—either by a reader within the dispensing system or a reader thatis in communication with the system—and the scanned code will be used toset the overrun, or other parameters obtainable from a bag label, forthe system.

In addition to being able to dynamically control the overrun forpurposes of creating a desired dispensed product, the overrun controlsystem described herein may be used to dynamically control the amount ofair (or other gas) introduced into the feed line to the freezingcylinder 2500 to control and enhance the freezing/refrigerationoperation of the system.

For example, the freezing characteristics of a product within thefreezing cylinder will typically vary with the amount of air within thefreezing cylinder 2500. If the system determines that the freezingoperation is not proceeding in a desired manner (e.g., throughmonitoring of the refrigerant return line from the cylinder) the systemcould dynamically adjust the amount of air (or other gas) provided atthe input of the freezing cylinder to adjust the overall operation ofthe freezing system. In this example, during an initial freeze operationor a defrost-refreeze operation, adequate air must exist in the cylinderfor the desired overrun amount. In such circumstances, it may not benecessary to introduce any additional air into the feed line. In othercircumstances, however, monitoring of the refrigeration return mayindicate that the overrun has dropped to an undesired level and moresignificant introduction of air into the cylinder may be warranted.

Referring back to FIG. 2B, during operation of the dispensing system asshown, the ingredient—potentially mixed with provided gas at junctionpoint or passage 2400—will be pumped by the pump 2300 into the freezingcylinder 2500 where it will be frozen. While the freezing cylinder maytake many forms, one of which is discussed in more detail below, it cantake the form of a refrigerated cylinder structure including a beaterbar driven by a motor. Through operation of an associated refrigerationsystem, the temperature within the freezing cylinder 2500 may becontrolled to freeze the ingredients within the freezing cylinder 2500to a desired product consistency and produce, for example, soft-serveice cream.

It should be noted that, in the depicted example, both the ingredientsupply element 2700 and all components and connections of the systemthat directly contact the ingredient are located within the ingredientrefrigeration compartment 2600. In particular, in the example, the pump2300, the air check valve 2018, any sensors 2402 and/or 2306, and theconnecting lines feeding from the supply element 2700 to the pump andfrom the pump output and junction 2400 are all entirely or, for the linefrom the pump to the freezing cylinder 2500 substantially (e.g., morethan 65%) within the refrigeration compartment 2600. This arrangement isthus of benefit in that it permits the system to maintain all of theingredients within the system and any ingredient/gas mix provided to thefreezing cylinder within a controlled temperature range. For ingredientsincluding, for example, any previously pasteurized dairy components,this ability to control the temperatures to which they are subjected tois significant.

During operation of the system as show in FIG. 2A, the pressure withinthe freezing cylinder may be impacted through operation of the ventingvalve or assembly 2028. For example, under circumstances where it isdesirable to avoid the build-up of pressure within the cylinder 2500,the venting relief valve assembly 2028 may be operated such that thevent is open, such that gas or material within the cylinder 2500 willtend to flow through the open vent and maintain the pressure within thecylinder 2500 at a desired level. As described above, the ventingassembly 2028 may be opened through actuation of the vent control airvalve 2026.

One circumstance in which it may be desired to actuate the vent controlelement 2028 to open the provided vent is during an initial cylinderfill operation where the cylinder will typically be filed with air (oranother gas) at a time when operation of the pump 2300 is initiated topump ingredient (or another fluid such as a cleaning fluid) into thecylinder 2500. Under such circumstances, selective operation of the ventcontrol assembly 2038 can be performed to allow a passage for the gaswithin the cylinder 2500 to be vented to atmosphere, thus preventing anundesirable pressure build-up within the cylinder 2500.

As further shown in FIG. 2A, the dispense control valve 2030 may beactivated to cause a dispense valve within the system to open. Suchactivation of the dispense valve (an example of which is discussed inmore detail below) will result in a discharge of product from thefreezing cylinder 2500.

Considering the above, it may be noted that the described systemprovides an effective and efficient system for delivering an ingredientfrom an ingredient supply element (e.g., element 2700), to a productformation chamber (freezing cylinder 2500 in the example) through a pump2300. It may also be noted that the disclosed system provides aneffective system for dynamically controlling the intermixing of apressurized gas into the product supply line of a sealed and pressurizedfood preparation and dispensing apparatus.

FIG. 2C illustrates the configuration of the system as configured for aself-cleaning operation. As will be apparent from a comparison of FIG.2B and FIG. 2C, the components and connections within the system aresubstantially as depicted as in FIG. 2B except that: (a) the systeminput connector 2610 is not coupled to the system self-cleaning port2800, but is rather coupled to the output of an ingredient supply source2700); and (b) the system is configured in a manner wherein the systembypass passage 2900 is enabled such that material dispensed from thefreezing cylinder 2500 will flow into the bypass passage. In general,the various components previously discussed will operate as previouslydescribed.

Referring to FIG. 2C, the components of the illustrated systemassociated with the self-cleaning operations of the system that have notbeen previously discussed will first be described.

As reflected in the exemplary system, the illustrated system includes awater supply line 2802 that (while not illustrated in FIG. 2C)terminates in a coupling suitable for attachment to a suitable source ofwater, such as a municipal water supply. A pressure transducer 2804 maybe used to detect the pressure at the water supply line to detect thepresence of a suitable water supply at a suitable pressure level. In oneembodiment, the output of the pressure transducer 2804 may be connectedto a system controller configured to place the system into a lock-out(or disabled state) whenever the input water pressure is below a desiredminimum water pressure (e.g., 45 PSI).

As reflected in FIG. 2C, the exemplary system also includes a drain line2806 that extends outside of the illustrated dispensing system that canterminate in a feature (e.g., a hose-like element) that may bepositioned to drain fluids from the dispensing system into a suitabledrain receptacle (e.g., a drain leading into a municipal drain system).

In the exemplary embodiment, the input water supply is provided at theinput of a first electrically controlled water valve 2808 that can beactuated to control the provision of water to the input of a cleaningcircuit that includes heating element 2810. In the exemplary embodimentof FIG. 2C, a temperature detection device 2812 is provided at theoutput of the heater and may be used to monitor the temperature of thewater exiting the heater.

It the example of FIG. 2C, it may be noted that the input to the heatingelement is coupled, through an optional check valve 2815, to the outputof the bypass passage 2900. Thus, it will be appreciated that, duringoperation of the system in the self-cleaning mode, the heater—dependingon the activation state of the valves 2808 and/or 2032—may receive atits input material discharged from the freezing cylinder 2500, fluidfrom the water supply 2802, or a mix of both.

As is further depicted in FIG. 2C the output from the heater 2810 isprovided to a junction point 2814. That junction point is fluidlycoupled to the system self-cleaning connection port 2800, the input toan electrically controlled drain valve 2816, and to the output of anelectrically controlled cleaner valve 2818. As also shown in the figure,the input to the cleaner supply valve 2818 is coupled to the output of asource of cleaning and/or sanitizing material 2820. Although notillustrated in FIG. 2C, check-valves may be placed within theillustrated lines to prevent backflow from the drain 2806 into thesystem, to prevent backflow from the system into the source of cleaningand/or sanitizing material 2820, or back into the heater 2810.

During operation of the disclosed embodiment in the self-cleaningconfiguration, the heating element 2810 may be used for heating fluidsthat are used during the self-cleaning operation.

In the example of FIG. 2C, the heater 2810 takes the form of an electriccartridge heater. It may be appreciated, however, that the use of such aheater—or indeed the use of a separate heating element—is exemplary onlyand that alternative approaches may be used to provide the heated waterused within the disclosed system. For example, instead of a cartridgeheater another form of heating device, such as an induction heatingdevice wherein the tubing holding the water is heated through inductionmay be used. As a further example, a heat trace could be applied to theexterior portion of the tubing holding the water and activated to heatthe water within the tubing. Additionally, or alternatively, instead ofhaving a stand-alone heating element, some or all of the water or otherfluids used within the disclosed system could be heated, throughoperation of the freezing cylinder 2500 in a heating mode (e.g., wherehot discharge gas from the condenser is fed back through the cylinderfor heating the cylinder contents through, for example, a reversingvalve within the refrigeration system). In such alternate embodiments,the water or other fluid to be heated could be pumped into the freezingcylinder 2500 and the freezing cylinder operated to heat the contents.

In general, through the use of the dedicated heater 2810—or an alternateheating system as described—when water or fluids during theself-cleaning operation of the present system may be heated to a levelthat would be appropriate for the sanitizing of a food-contact surface(e.g., a temperature at least at a minimum effective temperature ofapproximately 171° F.).

In some embodiments the system may be configured to ensure that anappropriate amount of fluid is flowing through the circuit containingthe external heater 2810 before the heater is activated. This is becauseactivation of the heater 2810 in the absence of adequate fluid flow maydamage the heater and/or shorten the useful life of the heater.Alternatively, a heater that is not susceptible to dry-fire damage maybe used. To ensure that adequate fluid flow exists, the systemcontroller (or a dedicated heater controller) could receive signalsindicative of fluid flow through the system and only activate the heateronce such signals indicate the presence of suitable flow. Such signalscould take the form of pressure measurements at the input and at theoutput of the pump 2300 (such as those provided by sensors 2306 and2402), since the pressure differential across the pump 2300 may providean indication of the extent of fluid flow through the pump. In suchexemplary embodiments, the controller may be configured to activate theheater only if a suitable pressure differential is detected.Alternatively, direct flow measuring devices could be used (as anembodiment of sensor 2306 or in the form of an additional sensor coupledto the input or output of the heater 2810) and the heater 2810 may beconfigured to activate the heater only if adequate fluid flow isdetected.

A still further approach for protecting (and/or monitoring) the properoperation of the heater may be to provide temperature sensors at theinput and at the output of the heater. The presence of an inadequatetemperature change, or an out-of-range temperature measurement, couldindicate the presence of inadequate fluid flow and/or heater failurethat would warrant deactivation of the heater.

As described above, the output from the heater 2810 may be fluidlyconnected to a junction point 2814 that may be fluidly coupled to theoutput of the cleaning supply valve 2818 and to the input of a draincontrol valve 2816. The described junction point may also be fluidlyconnected to the self-cleaning receiver port 2800.

As may be appreciated, the components and connections discussed above inconnection with FIG. 2C may provide a system that can, among otherthings:

(a) drain material from the freezing cylinder 2500 (by dispensingmaterial from the cylinder 2500, through the bypass passage 2900,through the heater 2810, and—through the drain control valve 2816—intothe drain);

(b) drain fluids and material from the heater 2810 and the linesconnected to the heater by activating the drain valve 2816;

(c) inject water—and potentially heated water—into the cylinder 2500through a path flowing from the water supply source 2802, through thewater fill valve 2808, through the heater 2810, through the systemconnection port 2800, and through the pump 2300 into the cylinder; and

(d) inject a cleaning and/or sanitizing material into the fluidscirculating through the system through activation of the cleaner controlvalve 2818.

In addition to the above, it will be appreciated that—during aself-cleaning operation—pressurized gas may be injected into the fluidcirculating through the system through operation of the air supply valve2016 (as discussed above). The injection of gas into the system during aself-cleaning operation may be useful to, for example and withoutlimitation, control or adjust the pressure within the system during aself-cleaning operation and/or provide a degree of fluid agitation topromote cleaning. Further, in embodiments where alternative sources ofgases are available for use within the system, a pressurized gas havingvarious cleaning and/or sanitizing properties may be injected into thefluids circulating within the system either in place of, in addition to,or at different times from, the injection of a cleaning and/orsanitizing material into the system through use of the cleaner controlvalve 2818.

Referring to FIG. 2C, aspects of an exemplary self-cleaning operationwill be discussed.

At an appropriate time, a user of the system may place the system in theconfiguration as reflected in FIG. 2C. (Some exemplary specific examplesof how this may be done are provided below). Once the system controllerdetermines that the system is in the appropriate configuration (e.g.,through user confirmation, automatic verification through system sensorsand/or a combination of the foregoing or other methods) the system maybegin the process of evacuating the freezing cylinder 2500 of anyproduct within the cylinder 2500. This evacuation step may beaccomplished by activating the dispense valve assembly 2032 to permitthe flow of material from the cylinder 2500 through the heater 2810(which need not be activated during this step) and through the drainvalve 2816 into the drain 2806. During all or a portion of this step,the water fill valve 2808 or air inject valve 2016 may be activated toprovide water or air to help flush out any product within the cylinder2500. Alternate embodiments are envisioned wherein, prior to and/orduring the evacuation step described above the temperature within thecylinder 2500 is elevated to warm the cylinder contents to either softenor liquify the contents to promote the speed and effectiveness of theevacuation step. Still alternate embodiments are envisioned wherein thesystem is configured such that the all or part of the evacuation stepoccurs at a time where product can be dispensed out of the faceplatesuch that all or some of the product is evacuated through a conventionaldispense operation.

The product evacuation step may be terminated once it is presumed,inferred, or detected that all (or substantially all) of the productwithin the freezing cylinder 2500 has been discharged. Proper evacuationmay be presumed by running the system as described above for apredetermined time period with the period selected to ensure productevacuation in most all expected operating conditions. Alternatively, oradditionally, proper product evacuation may be inferred by, for example,monitoring the temperature of the fluid provided to and flowing from thefreezing cylinder 2500, or just the temperature of the fluid flowing outof the heating element 2810, and inferring that all of the product hasbeen eliminated when the sensed temperature is at a particular level(e.g., the temperature of the expected water supply). Still further,proper product evacuation may be alternatively, or additionally,detected by monitoring some characteristic of a fluid within the system,such as the opacity of the fluid, which can provide an indication of thepresence of residual product. Still further, pressure measurementswithin the system can be used to determine the adequacy of the drain2806 for purposes of system operation. In embodiments where the adequacyof the drain is determined, the pressures within the system can bemonitored and the detection of a pressure at or above a specific leveland/or the detection of a change in the pressure signature, can providean indication that the drain capability 2806 is inadequate for thedesired system operation and/or that the characteristics of a previouslyproperly performing drain, are no longer adequate (e.g., because of aclog, or a backup). In embodiments, where drain monitoring isimplemented, the detection of an inadequate (or potentially clogged)drain can result in the provision of a notice (visual, audible, orcommunicative—e.g., text, e-mail) notice to a system user and/or servicetechnician.

Once the system determines that the system has been evacuated of anyresidual product, it may then proceed to a step where the system isfilled with water to a level that is sufficient to support the cleaningoperation. This may be done by activating the pump 2300 at a time whenthe water fill valve 2808 is activated to permit the flow of water intothe cylinder 2500. Note that during this step—as well as the productevacuation step—the cylinder vent control valve and vent relief assembly2026 and 2028 may be activated if necessary to control the pressureswithin the cylinder 2500. During all (or substantially all) of thisstep, the drain valve 2816 may be closed such that the fluid within thesystem will circulate from the freezing cylinder 2500, through the fluidline containing the heater element 2810, and through the pump 2300 andback into the cylinder 2500.

During part of, or after, the fluid fill step described above, thesystem may activate the heater 2810 to begin heating the fluid flowingthrough the system. At the same time—or before or after—the heatingoperation is initiated, the system may activate the cleaner valve 2818to cause cleaning and/or sanitizing solution to flow from the cleanerand/or sanitizing supply element 2820 into the circulating fluid. Thetiming of the operation of the cleaner valve 2818 may vary and may beimpacted by whether the specific cleaning and/or sanitizing solutionprovided by the supply 2820 requires a fluid within a specifictemperature range for dissolution and/or activation.

The amount of cleaning and/or sanitizing solution provided during thisstep of the self-cleaning process may be controlled in a variety ofways. In accordance with one embodiment (discussed in more detail below)the user of the system may be required to place a pre-portioned amountof cleaning and/or sanitizing solution into a supply compartment withinsupply element 2820 before the initiation of the cleaning operation. Insuch embodiments, there will be no need for the system to dynamicallycontrol the provision of the cleaning and/or sanitizing material to thejunction 2814.

In accordance with other embodiments, a metering system—such as apumping system or a flow-detection system—may be used to monitor theamount of cleaning and/or sanitizing material being injected into thecirculating fluid during this step and a system controller could be usedto control the cleaner valve 2818 and/or a pump to regulate and controlthe amount and timing of the provision of cleaning and/or sanitizingmaterial to the junction 2814.

After or during the step in which the fluid within the system is heatedand the cleaning and/or sanitizing material is provided to, and mixedwith, the circulating fluid, the cleaning fluid may be circulatedthrough the system repeatedly. During this step, additional operationsmay be performed to enhance the effectiveness of the cleaning system.For example, one or more of the following actions may be performed atthe same time, or at different times and in different orders, tofacilitate cleaning and sanitization of the various components withinthe system:

-   -   (a) activation of the air supply valve 2016 to inject        pressurized gas into the circulating fluid;    -   (b) activation of the dispensing valve assembly 2032 repeatedly        to move the dispensing valve elements and potentially better        expose them to the circulating cleaning fluid and/or to agitate        the circulating cleaning fluid;    -   (c) activating a beater bar assembly within the freezing        cylinder 2500 to potentially better expose their surfaces to the        circulating cleaning fluid and/or to agitate the circulating        cleaning fluid, such activating including the acts of rotating        the beater bar assembly in either direction and/or moving the        beater bar assembly back and forth in the absence of a complete        rotation; and/or    -   (d) change the operating speed of the pump 2300, or temporarily        cease operation of the pump, or reverse the pump, to impact the        flow of the cleaning fluid through the system.

Once the above cleaning step has been completed, or during or shortlythereafter, the heating element 2810 can be deactivated and thecirculating cleaning fluid may be discharged from the system through thedrain 2806 through activation of the drain valve 2816.

In accordance with one embodiment of the present invention, some or allof the heated fluids used during a self-cleaning process may be activelycooled prior to being discharged from the system. Such cooling may beuseful in applications where it is desirable to ensure that thetemperature of any liquids discharged from the system is below a certainthreshold amount, such as an application where the discharge drainscould be damaged by liquids at certain high temperature or anapplication where applicable regulations preclude the discharge ofliquids into drains above a certain temperature level. Additionalreasons for monitoring the exiting fluids have been described inApplicant's co-pending U.S. patent application Ser. No. 16/124,701,which was filed on Sep. 7, 2018, the contents of which are herebyincorporated by reference. This cooling may be accomplished by operatingthe freezing cylinder 2500 to cool the fluid within the cylinder untilit is presumed, inferred, or detected that the fluid within the systemis at an appropriate level. Additionally, or alternatively, this coolingmay be accomplished through quenching where the high temperaturedischarge fluid is mixed with cooler water from the water supply 2802through operation of the control valve 2808. In still furtherembodiments, the activation and open extent of the drain valve 2816 canbe controlled based—all or at least in part—on the output value from thetemperature sensor 2812. In such embodiments, the system can eitheravoid any flow of discharge into the drain until a desired temperaturelevel of the discharge has been reached and/or control the rate ofdrainage flow into the drain based on such output.

The temperature of the liquid being cooled in the cylinder prior todischarge may be detected or inferred in a variety of ways. Inaccordance with one embodiment, a temperature sensor may be positionedwithin the cylinder 2500 to provide an indication of the temperature ofthe contents of the cylinder. In accordance with another embodiment,instead of or in addition to the described sensor, detection of thetemperature of the refrigerant within a portion of the refrigerationcircuit may be used to infer the temperature of the liquid in thecylinder since the temperature of the departing refrigerant will beapproximately equal to the temperature of a water-based liquid in thecylinder. The alternate embodiments that do not involve a temperaturesensor within the cylinder 2500 may be beneficial, in certainapplications, because they avoid the burdens imposed by a including aseparate temperature sensor, for example in, in terms of cost, componentcount, and cylinder penetrations.

In one exemplary embodiment all liquids discharged from the system aspart of a self-cleaning process are cooled as needed to ensure that thedischarge temperature of the liquids is no greater than approximately140° F. In other exemplary embodiments, the discharged liquids arecooled as needed to ensure that all discharged liquids are at or lessthan 100° F.

In addition to providing a fluid circuit for the self-cleaning andsanitization of all (or substantially all) of the components andstructures that come into contact with the food product or the productingredient supply for the dispensed product, the exemplary system ofFIG. 2C also provides a circuit for flushing the cylinder vent reliefassembly flush passage 2036 and the cylinder venting assembly 2028. Asillustrated, this flushing circuit comprises a vent flush valve 2208that, when activated, will cause water from the water supply to flowthrough the valve 2208, into and through portions of the cylinder ventrelief assembly flush passage 2036 (one manner of many will be discussedbelow) and into a discharge line 2730 that is fluidly coupled to thedrain 2806. The vent purge valve 2034 and the cylinder vent reliefassembly flush passage 2036 that are arranged such that activation ofthe vent purge valve 2034 will inject pressurized gas into theconnection to the cylinder vent relief assembly flush passage 2036.Through activation of the vent flush valve 2208 and/or the vent purgeair valve 2034, water, pressurized gas, and/or a mixture of the two maybe passed to and through the cylinder vent relief assembly flush passage2036 and into the drain 2806 to clean, flush and/or purge any materialsthat may have collected within the cylinder venting path.

It should be noted that—because the portions of the cylinder ventingpath cleaned, flushed or purged through the described circuit do notcome into contact with any food product to be dispensed or ingredientsfor food products to be dispensed—it is not critical that they beexposed to any cleaning and/or sanitizing solutions during aself-cleaning operation.

FIG. 2D illustrates an alternate arrangement for the piping andinstrumentation of the disclosed system. It will be appreciated that thearrangements shown in FIGS. 2A-2D are exemplary only and that alternatearrangements can be implanted without departing from the teachingsherein.

It should also be noted that because the described components forcleaning, flushing and/or purging the cylinder venting assembly 2028 arenot fluidly connected to the input line to the freezing cylinder and mayoperate when the dispensing system is configured to prepare and dispenseproduct, the cylinder vent assembly 2028 may be operated during part of,or separate from, a self-cleaning process as described previously. Thus,the described system for cleaning, flushing and/or purging the cylinderventing assembly 2028 may be activated, for example, on a periodic basisduring system operation, each time the system activates the cylindervent assembly control valve 2026, or at times during which product isbeing produced and/or dispensed from the system.

As will be appreciated from the above discussion, the product dispensingand self-cleaning functionality of the described example may bepartially enabled by certain fluid connections and/or the ability of thesystem to be configured such that the bypass passage 2900 is excluded orincluded in the flow of product that is discharged from the freezingcylinder 2500. These aspects of the disclosed system may be provided—inone embodiment—by a specially designed faceplate assembly.

Turning now to FIGS. 3A-3E, in general, the faceplate 3000 is used toenable and support several of the described operations of the disclosedsystem including a dispensing operation where product within thefreezing cylinder is dispensed for use or consumption; a ventingoperation, where a vent structure is operated to adjust the pressurewithin the freezing cylinder; and a self-cleaning operation where thesystem is operated in such a manner that key components of the systemare cleaned and/or sanitized. In the exemplary embodiment of FIGS.3A-3E, the faceplate is formed from an acrylic material, or any othersuitable material as would be known to those skilled in the art and inreceipt of the teachings and disclosures contained herein.

Referring first to FIGS. 3A and 3B, front and rear views of theexemplary faceplate 3000 are provided. As reflected in the figures inthe illustrated example, the faceplate is generally rectangular in shapeand defines four passages through the faceplate 3002A, 3002B, 3002C,3002D, at locations generally near the four corners of the rectangle,for receipt of faceplate attachment elements for securing the faceplateto the front of the unit. Each faceplate attachment element may take theform of a threaded bolt with a knob attached at one end, where eachthreaded bolt is sized to fit through one of the openings 3002A-3002Dand to be received within a nut-like opening secured within the frontface of the dispensing system. In such an embodiment, attachment of thefaceplate to the dispensing system may be readily accomplished bypositioning the faceplate 3000 at the proper location with respect tothe overall dispensing system, feeding the attachment elements throughthe openings and then tightening the attachment elements to form a sealbetween the faceplate 3000 and a front open portion of the freezingcylinder 2500. An exemplary depiction of a faceplate to the overalldispenser system in the manner described above is generally set forth inFIG. 1A.

In the embodiment described above, the faceplate 3000 may be easilyremoved from the other components of the system by simply unscrewing andremoving the described attachment elements from the main housing of thedispenser and then pulling the faceplate 3000 away from the maindispenser body.

In the embodiment described above—as well as any other embodimentsassociated with a faceplate 3000—structure may be provided to detect theabsence or presence of the faceplate. For example, in one embodiment,one or more limit switches could be placed between a feature of thefaceplate 3000 and the main dispenser housing where the condition ofsuch limit switches would indicate the presence or absence of thefaceplate 3000. In alternate embodiments, a magnetic or other detectablestructure may be fixed within the faceplate 3000 and a sensor may belocated at an appropriate location of the dispenser main housing, wherethe detector will detect the magnet or other material when the faceplate3000 is properly positioned. In such exemplary embodiments, the systemcontroller may use the provided information concerning the faceplate3000 to adjust the operation of the system. For example, in situationswhere the faceplate 3000 is detected to be not present, the controllermay put the system in a lock-out condition and prevent the initiation ofall or certain system operations until the faceplate 3000 is detected asbeing properly positioned.

Referring back to FIGS. 3A-3B, it may be seen that the exemplaryfaceplate further defines an upper recess area 3004 for receipt of thestem of a dispense valve member (discussed in more detail below). In theillustrated example, the front portion of the faceplate further definesa generally diamond-shaped recess 3006 sized to receive elements formingpart of a cylinder vent-relief assembly 2028 (discussed above generallyand discussed in more detail below with respect to an exemplaryembodiment). Although not fully visible in FIG. 3A, the faceplatefurther defines a passage extending through the faceplate 3007 having afront opening positioned near or at the approximate center of the recess3006. An additional passage 3041 extends to the cylindrical space infront of area 3007 for air actuation of the vent-relief assembly whenactuated in the controlled venting mode.

As further reflected in FIG. 3A, the faceplate defines a downwardlyextending dispense spout 3008 in which are optionally formed a pluralityof generally cylindrical openings (only one of which—3010—is separatelylabeled in FIG. 3A). The openings 3010 may be used to receive dowl pinsthat can be used as connecting features for the optional securement of adispensing cap and/or a blocking cap to the bottom opening of thedispense spout 3008.

The dispensing caps usable with the disclosed exemplary embodiment maytake the form of a cap with an open end formed to having a specificcross-sectional shape. In general, the purpose of such a dispensing capis to control the aesthetic appearance of the dispensed product. Oneexample of a dispensing cap suitable for use with disclosed system isthe dispensing cap 4000 reflected in FIG. 4A which has an open crosssection in the shape of a star.

FIG. 4B illustrates one exemplary blocking cap 4500 that may be used inconnection with the disclosed system. In general, the blocking cap 4500is a cap that, when secured to the open end of the dispense spout 3008of the faceplate will prevent the dispensing of any product from thedispense system 1000. The blocking cap may be connected directly to thedispense spout 3008 to block the dispending of product or, optionally,may be secured over a dispensing cap 4000. In either embodiment,attachment of the blocking cap 4500 to the faceplate 3000 will preventthe dispensing of food product out of the opening of the dispense spout3008. In certain embodiments the blocking cap 4500 may include a magnetor other detectable material and the main dispense system housing mayinclude a sensing device (such as a magnetically activated switch) fordetecting the presence of the magnet or other detectable material. Insuch embodiments, the system controller may use the signal from thesensing device to determine whether a blocking cap 4500 is properlypositioned with respect to the faceplate 3000.

Referring back to FIGS. 3A and 3B and, in particular to FIG. 3B the backportion of the exemplary faceplate 3000 is shown.

FIG. 3B illustrates the upper recess 3004 for receiving the dispensevalve stem (discussed below) and the backside openings of thepassageways 3002A-3002D through the faceplate for receipt of thefaceplate attachment elements.

As depicted in FIG. 3B, the exemplary faceplate also defines a large,generally circular-shaped recess 3012. This recess may be sized toreceive a suitable O-ring element to ensure a properly sealed fitbetween the faceplate and an external surface of the freezing cylinder2500 (or other feature associated with the main dispensing system). Theexemplary faceplate may further include additional recesses within thelarge circular recess 3012—such as the recess 3009 located in theapproximate center of the large recess—to permit receipt of other systemcomponents (such as a portion of a beater-bar assembly). Alternateembodiments are envisioned wherein the identified O-ring element (andsome or all or any other O-rings or surface sealing elements used in thesystem) are replaced with a suitable sealing material which could bemolded or bonded to the faceplate material. Such sealing structures caninclude, for example and without limitation, over molded features and/orcomponents formed from resilient thermoplastic polyurethane (“tpu”) orother suitable elastomeric material which can create a seal.

In the example of FIG. 3B, the backside of the exemplary faceplate 3000further defines two positioning openings 3014A and 3014B which may beused to interface with positioning elements (e.g., dowel portions) toenable proper positioning of the faceplate 3000 relative to theremainder of the dispensing assembly to ensure proper alignment of thefaceplate 3000 with respect to the other system components. Openings3014A and 3014B may be configured to ensure that the faceplate 3000 isoriented correctly and not installed upside down or at right angles toits proper orientation.

In addition to the features described above, the exemplary faceplate3000 of FIGS. 3A and 3B further defines the backside opening of thepassageway 3007, previously described as extending from the backside ofthe faceplate to the front of the faceplate. As may be noted, thebackside opening of the passageway 3007 opens into a portion of thefaceplate 3000 that is within the larger circular recess 3012. As such,when the faceplate 3000 is affixed to the freezing cylinder 2500 or tothe main dispensing system, the passageway 3007 will be available toserve as a vent passage to permit the flow of air, gas, or materialsfrom within the freezing cylinder 2500, through the faceplate 3000, tothe exterior environment. As will be described shortly, this passageway3007 forms part of the structure of the cylinder vent relief assemblyflush passage 2036 and vent relief assembly 2028.

As further reflected in FIG. 3B, the exemplary faceplate defines a largepre-dispense cavity 3016 that has a front generally curved portion and agenerally rectangularly shaped rear opening. A dispense bore 3024extends from the bottom of the pre-dispense cavity 3016 and down throughthe output of the dispense spout 3008. As will be described in greaterdetail below, during a dispense operation, food product from within thefreezing cylinder 2500 will flow into the pre-dispense opening 3016through its rear opening and, if the dispense valve is properlypositioned, down through the bore 3024 and through the output opening ofthe dispense spout 3008.

As partially reflected in FIGS. 3B and 3C, the backside of the faceplate3000 further defines a rear opening 3060 that opens into a cleaningbypass passageway 3900 formed within and through the faceplate. In theexemplary faceplate of FIG. 3B, the bypass passageway 3900 extends fromthe rear opening 3060 into the interior of the bore 3024. FIG. 3Cprovides a front view of the faceplate 3000 that shows an exemplarybypass passageway 3900, beginning at a cylindrical end face opening 3061perpendicular to bore 3024, extending upward from this beginning point,changing direction horizontally and penetrating the rear face offaceplate 3000 at rear opening 3060. It will be appreciated that thedescribed position and orientation of bypass passageway 3900 isexemplary only and that other arrangements and configurations can beused without departing from the teachings of this disclosure.

FIG. 3D provides a backside-looking view of the faceplate 3000 thatdepicts the same structures described above from a differentperspective. As will be appreciated, in the example of FIG. 3D, thecleaning bypass passage 3900 includes a first portion, illustrated asextending in a substantially horizontally in FIG. 3D and a secondportion that extends downwards from the first portion and opens to thebottom of the faceplate near the label line for the downspout 3008. Aswill be appreciated from the depiction in FIG. 3D, in this embodimentthe downward opening of the cleaning bypass passage 3900 is in the samedirection as the dispense opening 3024, but is displaced horizontallyfrom the dispense opening.

This bypass passageway 3900 may operate as the bypass passageway 2900discussed above in connection with FIGS. 2A-2C. In particular, thebypass passageway 3900 may function as the bypass passageway 2900described above in that it can be used to provide a passageway from theinterior of the freezing cylinder 2500 to the input to the heater 2810(when used with, e.g., the blocking cap 4500). It should be appreciatedthat alternate approaches can be used to form or activate the bypasspassageway 3900 that do not involve the use of a blocking cap. Forexample, alternate embodiments are envisioned wherein the dispensingvalve is constructed so as to move to a position where discharge ofproduct or fluid from the system is blocked such that the bypasspassageway is enabled. Still further embodiments are envisioned whereina structure that contains a pelletized or powered cleaning agent orsanitizer is used in place of blocking cap 4500 such that attachment ofsuch a structure to the faceplate both provides the (or a) cleaningand/or sanitizing agent and serves to activate the bypass passageway.

In the example of FIGS. 3A-3D, when the blocking cap 4500 is NOT affixedto the faceplate, the bottom opening provided by the dispensing spout(or the opening of a dispensing cap 4000 attached to the faceplate 3000)will be open. As such, there will be a potential fluid path extendingfrom the interior of the freezing cylinder, through the faceplate andthrough the output of the dispensing spout 3008. Under these conditions,activation of the dispensing assembly within the system (discussed inmore detail below) will cause product or fluid to flow from thedispensing cylinder through the faceplate, and out the dispensing spout3008. Because of the flow path described above, there will be nothing tocause product or fluid to flow from the interior of the bore 3024,through the passageway 3900, and out the opening 3060 and there will beno, or an insignificant flow of product or fluid, through the passageway3900 under these conditions.

When the blocking cap 4500 is affixed to the faceplate 3000, however, itwill block the opening at the bottom of the dispense spout andactivation of the dispense assembly under these conditions, will causeproduct or fluid to flow form the interior of the freezing cylinder 2500through the faceplate, into the bore 3024 and back through the bypasspassageway 3900 and back through the opening 3060 in the rear of theface plate. Such opening 3060 can be fluidly coupled to the bypass line2900 such that a fluid connection may be made into the components andconnections used for the self-cleaning operation described above.

Turning to FIG. 3E, certain features of the faceplate 3000 related tothe dispensing assembly will be further discussed.

FIG. 3E provides a side cutaway view of the exemplary faceplate 3000with a cut taken at substantially the midpoint of the faceplate. As maybe understood from inspection of FIG. 3E and the previously discussedfigures, the faceplate 3000 defines a shaped bore 3014 that has an upperopening at the top of the faceplate (within the recess 3004) thatextends down to and through the opening of the dispensing spout 3008.

As further shown in FIG. 3E, the extending central bore 3014 may haveareas of differing diameter to define recesses and openings of differentsizes. In FIG. 3E, for example, the central bore 3014 further defines:an upper open area 3020 that (as discussed below) may be used toposition a sleeve bearing within the faceplate 3000; an intermediateopen area 3022 that (as described below) may be used to house a sealingO-ring within the faceplate the open area 3016 discussed above, and theopen bore 3024 (also discussed above).

The features within the faceplate reflected in FIG. 3E may be used toreceive components used for the dispensing of product from the interiorof the freezing cylinder 2500. Exemplary embodiments of such dispensingcomponents are discussed hereafter in connection with FIG. 5E and FIGS.5A-5D.

FIG. 5A illustrates a front view of the exemplary system with a portionof the front cover and various components not associated with thedispensing sub-system hidden. As reflected in the figure, the exemplaryembodiment of the dispending sub-system includes a pneumaticallyactuated air cylinder 5002 from which extends an air cylinder strokeshaft 5004. Activation of the dispensing air cylinder 5002 (for examplethrough activation of the dispense pneumatic solenoid 2030 discussedabove) will, in the example, cause the stroke shaft 5004 to retractwithin the cylinder 5002. In this example, deactivation of the aircylinder 5002 (e.g., through deactivation of the valve 2030 or a loss ofpower) will cause the stroke shaft 5002 to move to its original,extended, position. To ensure such movement, the cylinder 5002 mayinclude bias springs to hold the stroke shaft 5004 in a normallyextended position.

It will be appreciated that alternate dispense systems may beconstructed using the teachings of this disclosure wherein activating ofthe dispensing air cylinder 5002 could cause the stroke shaft 5004 toextend from the cylinder 5002.

The extent to which the stroke shaft 5002 extends and retracts inresponse to the activation of the air cylinder 5002 may be such that theextreme extension and retraction points are dynamically controlled foreach stroke of the cylinder (e.g., by controlling the amount of air orgas injected into the cylinder through controlled operation of thedispense valve 2030) or may—in some embodiments—be set to vary between afirst fully extended position and a second fully retracted position. Insuch embodiments, activation of the pneumatic cylinder will result in anoperation of the dispenser in an ON/OFF dispense mode such that theshaft is either in an OFF position, (such as the one illustrated in FIG.5B) where product or fluid within the freezing cylinder 2500 is blockedfrom passing dispense spout of the faceplate 3008, or in an ON positionwhere the shaft is retracted to a predefined distance to permit passageof product or fluid from the freezing cylinder 2500 and through thefaceplate 3000 and into the dispense spout 3008. As discussed above,this is exemplary only and alternative embodiments are envisionedwherein the pneumatic cylinder 5002 may be actuated in an approximatelylinearly controlled manner such that it may extend from a base restposition to an extreme retracted position, and to substantially anyintermediate position in between.

As reflected in FIG. 5A in the depicted example, the shaft 5004 from thepneumatic cylinder 5002 is coupled to a valve stem actuator in the formof lifter element 5006. As shown in the figure, the lifter element 5006has a cutout that is shaped to receive one end of a dispensing stem5008. In the exemplary embodiment the shape of the cutout of the lifterelement 5006 and the shape of the dispensing stem 5008 are such that thedispensing stem 5008 can easily slide in a front-to-back andback-to-front manner to cause the end of the dispensing stem 5008 toengage with, and disengage from, the lifter element 5006. However, oncethe dispensing stem 5008 is engaged with the lifter element 5006,movement of the lifter element 506 upwards or downwards (through theapplication of air or gas to the pneumatic cylinder 5002) will cause thedispensing stem 5008 to move upwards or downwards in a correspondingmanner.

FIG. 5B illustrates a sideview of the system of FIG. 5A. This figurethus shows how the stem 5008 is positioned within the dispensing faceplate 3000 and is retained in position by the face plate 3000 withrespect to its front-to-back (right-to-left in FIG. 5B) orientation withrespect to the lifting element 5006. As will be apparent from FIG. 5B,when the dispensing stem is positioned within the face plate 3000,removal of the faceplate 3000 from the overall dispensing system (e.g.,by un-screwing connecting elements and pulling the faceplate off thedispensing system body) will result in the dispensing stem 5008 beingdecoupled from the lifting element 5006.

In the illustrated exemplary embodiment, once the face plate 3000 (andthe retained dispensing stem 5008) is removed from the overalldispensing system, the dispensing stem 5008 can be readily separatedfrom the face plate 3000 by passing the stem (and the O-rings coupled tothe stem) through the discharge opening at the bottom of the face plate3000. (Note that this may require removal of any shaping ring cap 4000positioned about the dispensing spout 3008 of the faceplate). Such easyremoval of the dispensing stem 5008 may allow for replacement orinspection of the O-rings coupled to the stem 5008, cleaning orreplacement of the stem, and/or cleaning of the interior passage withinthe face plate in which the stem is located.

FIG. 5C provides an isometric view that further illustrates the mannerin which the dispensing stem 5008 may be received within the liftingmember 5006. As reflected in FIG. 5C, the lifting element 5006 definesan opening which, in the example, is a generally “T-shaped” opening thatis sized and arranged to receive a generally “T-shaped” arrangement atthe top end of the dispensing stem 5008. A sleeve bushing or sleevebearing (not illustrated) may be provided to prevent the stem fromwearing against the lifting element. A first sealing O-ring 5012 may beprovided at the bottom end of the dispensing stem to seal against thefaceplate when the dispensing system is not dispensing product. One ormore additional O-rings 5010 may be provided to help position thedispensing stem within the faceplate and form a seal keeping the productentirely contained within the cylinder 2500 or pre-dispense cavity 3016.

Note that FIG. 3E generally illustrates a first faceplate opening 3020within which any provided sleeve bushing or sleeve bearing may belocated and a second faceplate opening 3022 in which an additionalO-ring may be positioned.

Returning back to FIG. 5A, it will be noted that in the illustratedarrangement the lower portion of the dispensing stem 5008 (in theexample the face associated with O-ring 5012) is in a position where itblocks the upper portion of the face plate dispensing spout 5008 butdoes not extend into or to the bottom of the dispensing spout 3008. Aswill be apparent from the figure, in this position, the lower portion ofthe dispensing stem 5008 (to which a sealing O-ring 5012 is attached inthe illustrated example) will seal against an interior surface of thedispense bore to prevent discharge of product from the freezing cylinderthrough the exit of the dispense spout 5008. As described above, uponactivation of the pneumatic cylinder 5002, the dispensing stem 5008 canmove (up in the example) to provide an open flow port from the interiorof the freezing cylinder 2500 to the output of the dispensing spout 3008such that product can be dispensed from within the freezing cylinder. Aswill be apparent from FIGS. 3A-3D and 5A, when the dispensing stem 5008is positioned to prevent discharge of product from the freezingcylinder, the lower open end of the bypass passage 3900 is at a pointbelow the seal between the valve stem and the dispense bore.

Note that in the illustrated embodiment, the pneumatic cylinder 5002 canalso be activated to move the dispensing stem 5008 such that the bottomof the stem 5008 extends all the way (or approximately all the way) tothe bottom of the dispensing spout 3008 and/or past the opening of thedispensing spout (such that the bottom of the dispensing stem extendsoutwardly from the dispensing spout). Such “overdriving” of thedispensing stem 5008 may be useful, for example, during self-cleaningprocesses to force additional movement of cleaning solution through thesystem, and during dispensing operations, to “flush out” any retainedproduct within the dispensing spout that could later drip from thespout.

Activation and/or deactivation of the pneumatic cylinder 5002 (andactivation of the dispense solenoid 2030) may be accomplished in avariety of ways. The manner and method of activation may also varydepending on the operating state of the dispensing system.

For example, in certain embodiments, the dispensing system may include acontroller that monitors various conditions of the system and places thesystem in a “lock-out” state where the controller precludes activationof the dispensing valve 2030. For example, as otherwise discussed morefully herein, a system controller may place the system in a lock-outstate if it is determined that the faceplate 3000 is not properlyattached to the dispensing system. As discussed above, thisdetermination may be made through the use of a limit switch that isactivated once the faceplate 3000 is properly positioned. FIG. 5Aillustrates the potential placement of one such exemplary limit switch5020. It may be appreciated that the controller can place the dispenserin a lock-out state upon the detection of other system conditions. Forexample, the controller may place the system in a lock-out state uponthe detection of one or more of the following conditions: (a) inadequateinput water pressure; (b) the absence of an adequate amount of productingredient; (c) inadequate input power; (d) undesired temperatureswithin the system; (e) absence of adequately regulated pressure; and/or(f) date and time restrictions (e.g., the system could be locked-outduring non-retail hours, on holidays, etc.). Still further, thecontroller may lock-out the dispensing system during periods wherein thefreezing cylinder is being defrosted and/or when the product within thefreezing cylinder 2500 is detected (or inferred) as not having certaindesired dispense characteristics.

In addition to being placeable into a lock-out state, the dispensingstructure of the present disclosure may be activated to operate thedescribed dispensing system during a self-cleaning operation toimplement the process described generally above. In such operatingconditions, the dispense solenoid may be activated to drive (andpotentially overdrive) the pneumatic cylinder 5002 to stroke thedispense valve stem 5008 open, closed and/or repeatedly open and closedto control the flow of product and/or fluids (e.g., cleaning fluids)from the freezing cylinder 2500 during a cleaning operation and/or toprovide a source of agitation to the product or fluids flowing throughthe system.

As a still further example, the dispense components of the presentdisclosure may be activated to dispense product from the freezingcylinder 2500. This may be done, for example, through the depression ofa dispense button (such as the dispense button 1040 of FIG. 1A) by auser or operator. In such an embodiment, depression of the dispensebutton will then send a signal to the system controller and, in theabsence of any control logic requiring otherwise, the controller maysend a signal to actuate the pneumatic dispense valve 2030, which—inturn—will cause an upward movement of the dispense stem and will resultin the dispensing of product form the system. In one embodiment, thecontroller may maintain the described state of the dispensing stem aslong as the user or operator is depressing the dispense button.

Embodiments are envisioned wherein the controller evaluates the systemcondition during periods when the dispense button is activated tocontrol the movement of the dispense stem 5008. For example, in someembodiments, the controller may operate to move the dispensing stem 5008to a product dispensing position upon the initial activation of thebutton but can then deactivate the dispensing valve causing movement ofthe stem to a non-dispensing position upon the passage of a certainamount of time since the dispense button was activated. Additionally, atthe conclusion of a dispensing operation (or periodically) the systemmay cause the dispensing stem 2008 to move downward to the end of thedispense spout 3008 to clear out any material that may have accumulatedwithin the dispensing spout.

In another envisioned embodiment, the dispensing stem 5008 may beactivated into a fully extended, non-dispense position immediately afterthe dispense button is pressed to forcibly expel any accumulation ofmatter from the dispense path before the dispensing stem 5008 is movedto a dispensing position. Similarly, the dispensing stem 5008 may bepulsed prior to, or after dispensing product.

It will be appreciated that the use of a dispensing button 1040 and apneumatic actuating cylinder 5002 to activate the dispensing system fora product dispense is exemplary only and that alternate dispensingsub-systems may be used without departing from the teachings of thepresent disclosure.

For example, alternate embodiments are envisioned wherein the dispensingsystem may use a stepper motor to move a stem attached to the liftingelement 5002. One such embodiment is shown in FIG. 5D where the shaftcoupled to the lifting element 5002 is coupled to an electrically drivenstepper motor assembly 5030. In the exemplary embodiment, the outputshaft of a stepper motor with the assembly is coupled to a pinion 5032connected to a rack 5034 to translate rotary motor shaft motion intolinear motion. In this example, springs 5036 are used to normally biasthe dispensing system to a closed position. As will be apparent from aninspection of FIG. 5D in the illustrated embodiment, activation of thesystem (e.g., through depression of a dispense button) may causeelectrical signals to be provided to the stepper motor resulting in thedesired movement of the dispense stem.

Note that the use of a dispensing button is also exemplary and thatother user interfaces may be used in place of, or in addition to, such astructure. For example, as shown in FIG. 5D, a spring-loaded lever 5040that is coupled to a potentiometer may be used to activate the dispensesystem. In such an embodiment a user or operator would pull down on thelever 5040 (rather than depress a button) and the extent to which thestepper motor assembly 5030 is activated will vary depending on theextent to which the lever is moved. One benefit of such a leveractuating device is that it can mimic the user experience commonly usedwith a conventional soft-serve ice-cream dispenser.

It may be appreciated that all of the electronically controlled dispensesystems described herein (including both the pneumatically operated andstepper motor embodiments discussed above) are such that they may betuned—and, in particular—dynamically tuned to align with differentoperation conditions, differing operating states, and different desiredusages for the disclosed systems.

Thus, for example, an operator or servicing agent can—throughappropriate configuration of the system—control the maximum rate ofproduct dispense through changing the manner in which the controlleractivates the dispense sub-system (e.g., to adjust the amount of timethe valve is open in response to a single depression of a dispensebutton, to adjust the stroke of the dispense stem 5008 upon activationof the cylinder 5002, etc.). Moreover, the disclosed dispensing systemallows the controller to automatically adjust—or dynamically change—thedispensing performance of the system. For example, if the system is onethat is capable of detecting the viscosity of the product within thefreezing cylinder, the system may adjust the dispense characteristics inresponse to the detected (or inferred) viscosity such that the rate ofdispense will vary depending on the product characteristics. Forexample, if the product is determined to have a relatively lowviscosity—such that a relatively significant volume will be dispensedover a given time period—the system may adjust the amount of time thedispense stem 5008 is open for a given depression of the dispensebutton. Alternatively, if the determined viscosity is high, the dispensetime could be extended. Still further, if the viscosity is below aminimum acceptable valve, the system may prevent dispensing entirelyand/or limit the ability of a user to fully open the dispense valve tocontrol the dispense velocity. Still further, the dispensecharacteristics may be varied depending on the nature and/or type offood product to be dispensed from the system. Thus, the dispensecharacteristics for a “shake” product, may vary from that for a“soft-serve ice cream” product, which could vary from the dispensecharacteristics of a hot soup product. Because the present system useselectronically and/or pneumatically controlled devices to implement thedispensing functions, such variation in the dispense characteristics canbe efficiently implemented.

As briefly discussed above, in addition to being able to dynamicallyadjust dispensing characteristics of the disclosed system, the dispenserof the illustrated embodiment is also able to dynamically control (andrelieve) the pressure within the freezing cylinder. This is accomplishedthrough a novel cylinder vent relief assembly, one embodiment of whichis depicted in FIGS. 3A-3B and FIGS. 6A-6C.

Referring first back to FIG. 3A, and as briefly discussed above, it willbe noted that the front portion of the faceplate 3000 defines agenerally diamond-shaped opening 3006 and a vent relief passage (bore)3007 that extends through the faceplate 3000. As reflected in FIG. 3 ,the faceplate 3000 further defines a vent-relief activation passage thatfeeds into the interior of the faceplate 3000 and that opens to opening3041 at the back of the faceplate.

FIGS. 6A-6C illustrate how the openings and features describe above maybe used to provide a dynamically controllable, readily cleanable, andmechanically-actuatable cylinder vent relief assembly.

As will be apparent from the figures and the present disclosure, thecylinder vent relief valve or vent relief assembly 6000 of the presentdisclosure performs at least two distinct functions. Specifically in theillustrated embodiment, the vent relief valve assembly is used to both:(a) provide a relief path to vent cylinder pressure in response to acontrolled pneumatic signal and (b) and to act as an automaticover-pressure relief valve that provides a vent relief path as a resultof the pressure within the freezing cylinder reaching a certainthreshold pressure. [00204] As shown in FIG. 6A the illustrated cylindervent relief assembly 6000 is affixed to the front of the faceplateassembly 3000 using, in the example two screws.

FIG. 6B provides a more detailed, exploded view of the main componentsof the vent relief assembly 6000. As shown in the figure the assembly6000 includes a plug member 6002 formed of a resilient material. Theplug member defines an opening through which attachment elements (screwsor other threaded members in the illustrated example) may pass to couplethe plug 6002 to the faceplate 3000. Additionally, there exists a ventfeature 6003 wherein the cavity created between 6002, 3006 and 6004readily achieves equilibrium with the surrounding environment preventinga buildup in pressure with actuation of the assembly (e.g., when valve2026 operates causing displacement of piston element 6004 andcompression of spring 6010. Positioned behind the flexible plug member6002 is a vent relief piston element 6004 (that, in the illustratedembodiments, supports O-rings 6006 and 6008). A first spring element6010 is positioned between the plug member 6002 and the piston element6004 such that one end of the first spring element 6010 is receivedwithin a front cavity 6012 defined by the piston element 6004. In theexample of FIG. 6B, the front cavity is a closed cavity in that it isnot opened at its rear surface.

A poppet relief element 6014, which in the illustrated example supportsO-ring 6016, is provided that has an extending portion that fits withina rear cavity formed within the piston element 6008. A second springelement 6018 is positioned about the extending portion of the poppetrelief element 6014 that has one end extending into a rear cavity of thepiston element 6004. In the illustrated example, the rear cavity isclosed in that its rear surface is not open. In the example of FIG. 6B,the structure of the piston 6004 that defines the rear cavity may haveone or more cutouts to permit the passage of gas or fluids across thepiston.

FIGS. 6A-6C further illustrate the manner in which the cylinder ventrelief assembly 6000 is positioned within the faceplate 3000 andreflects the manner in which the assembly 6000 operates and may becleaned.

As reflected in the figures, and specifically FIG. 6C, when positionedwithin the faceplate 3000, a rear surface of the piston 6004 fits with acavity 6100 formed by a recess within the faceplate 3000. In theillustrated figure, the piston 6004 is held in place by the forcesprovided by the plug 6002 and the first spring element 6010. As furtherreflected by the figures, in the illustrated orientation, the poppetassembly is positioned against the side of the faceplate that definesthe opening 3007 (discussed above in connection with FIG. 3A) which, ifopen, would provide a passage from the inside of the freezing cylinder2500 to an open portion of the faceplate within the recess 3506.

In the orientation shown in FIGS. 6B and 6C, a portion of the cavity6100 on the backside of the piston element 6004 is sealed from theexternal atmosphere by O-ring 6006 and the previously described ventrelief activation passage 3041 passes from the back of the faceplate3000 to the cavity 6100. Because of this structure, activation of thevent relief valve 2026 (which controls the application of pressurizedgas to the passage 3041) will cause pressurized gas to flow from theaccumulator 2008, through the vent relief solenoid 2026 and into thecavity 6100. In the illustrated example, this flow of gas into cavity6100 will eventually cause a pressure build-up within cavity 6100 suchthat a sufficient force is created to force the piston 6004 to overcomethe forces holding the piston in a closed position (namely the forcesprovided by the first spring element 6010 and the plug 6002) and movethe piston 6004 to an “open position” (i.e., one where a pressure reliefpath is provided from the freezing cylinder). In the illustratedexample, the pressure release path may be visualized by consideringFIGS. 6B-6C in conjunction with FIGS. 3B-3D. Referring to such figures,it will be appreciated that—when the pressure relief path that iscreated as a result of piston 6004 moving to the open position—an openpath will extend from within the interior of the freezing cylinder 2500,through the opening (or bore) 3007 on the rear of the faceplate (FIG.3B), through the faceplate, through the opening created by the openpiston 6004 and into the cavity 3056 that extends between port 3050 and3052 (FIG. 3D). Both because of the pressurized nature of the freezingcylinder 2500, and because the opening 3007 is located above the openingfor port 3052, any gas or product that flows through the faceplate intocavity 3056 will be directed into and through port 3052. As describedpreviously, in the illustrated example, port 3052 is connected directlyto the drain such that any released gas, fluid and/or product, will flowthrough the port 3052 into the drain without passing through the drainvalve 2816.

As the piston 6004 moves to an open position, the force maintaining thepoppet element 6014 in a sealed, closed position against the openinginto the freezing cylinder 2500 will be reduced. As such, if thepressure within the freezing cylinder 2500 is of a sufficient magnitude,the pressure within the freezing cylinder 2500 can overcome the reducedforce acting against the poppet element 6014, and thus provide apressure release passage extending from the interior of the freezingcylinder, through the opening 3007, and through the faceplate 3000 intocavity 3056 (as described above). In this manner, the vent reliefsolenoid 2026 may be activated to control the pressure within thefreezing cylinder 2500 and in response to a pneumatic control signal.

As will be appreciated by further study of FIGS. 6B and 6C, because thepoppet element 6014 is spring biased against the faceplate, in part, bythe force produced by the second spring element 6018, and because poppetelement 6014 is positioned such that it can move against the force ofspring 6018 towards the piston 6004, there is the potential that thepressure within the freezing cylinder 2500 reaches a sufficientmagnitude that the poppet element 6014 moves to an open position, thuspermitting the flow of gas, fluid or product within the freezing chamberthrough the opening 3007, into the cavity 3056, out the port 3052, andinto the drain. Further, a buildup of pressure within the cavity 6100that can generate forces within the cavity 6100 sufficient to move thepiston 6004 to an open position and, thus, provide a pressure reliefpath from the cavity 6100, over the piston 6004 to the atmosphere. Inthis manner, the illustrated exemplary cylinder vent pressure reliefassembly 6000 may provide an automatic mechanical pressure relief valvefor releasing pressure from within the freezing cylinder 2500, suchthat—in the illustrated example—any flow of gas, fluid and/or releasedproduct from within the freezing cylinder is fed directly to the drainwithout passing through the drain valve 2816. Of note, the pressurerelieving aspects of the poppet element 6014 and the piston 6014 are notaffected by any sticktion of either of O-rings 6006 and/or 6008.

As will be appreciated from the teaching of this disclosure, thepressure required to activate the vent relief assembly 6000 throughapplication of a pneumatic control signal, and the pressure at which theassembly will automatically open as a result of overpressure within thefreezing cylinder 2500 may be set and adjusted through the sizing andthe selection of the spring elements 6010 and 6018.

In the example of FIGS. 6A-6C, the opening of the vent relief assembly6000 in response to the receipt of a pneumatic control signal from valve2026 may or may not result in the poppet element 2014 opening andproviding a pressure relief path from the interior of the freezingcylinder to atmosphere. As described above, whether the poppet element2014 will open will depend on whether the pressure within the freezingchamber is sufficient to overcome the reduced closing force that will beapplied to the poppet element 2014 under those conditions. FIG. 6Ddepicts an alternate embodiment where activation of the vent reliefassembly 6000 through the application of a pneumatic control signal willalways result in movement of the poppet element 2014 to an openposition.

In the embodiment of FIG. 6D, the vent relief assembly 6000 is similarto that described above in connection with FIGS. 6A-6C except that thepoppet element 6014′ is retained within an interior space within thepiston 6004′. In this configuration, whenever the piston 6004′ moves toan open position, it will pull the poppet element 6014′ with it.

As will be appreciated, because operation of the vent relief assembliesdescribed above may result in the passage of gas, fluid or othermaterials from the interior of the freezing cylinder, through thefaceplate, and across and through the vent relief assembly toatmosphere, there is the potential for product or materials to build upalong the described pressure relief passage. In certain embodiments ofthe present dispenser, components and features may be provided to cleanor flush out that passage. FIGS. 6C and 6D (in consideration with FIG.2A illustrate one such flushing system.

As discussed above in connection with FIG. 2A, the cleaning/flushingsystem may include a vent flush passage (bore) in fluid communicationwith a vent flush control valve 2208 configured such that activation ofthe vent flush valve 2208 will cause water to flow through the ventflush line to clean the venting system. In FIGS. 6C and 6D, this ventflush passage takes the form of the passage 3056 which extends throughthe faceplate from opening 3054 (as shown in FIGS. 3B and 3D) at theinlet to opening 3052 at the outlet. As may be seen in FIGS. 6C and 6D,the vent flush passage 3056 extends to a region of the faceplate withinwhich the second spring element 6018 and the non-sealing portion of thepoppet element 6014 (or 6014′ for the alternate embodiment of FIG. 6D)are positioned. As such, as water flows through the vent flush passage3056, it will tend to clean the surfaces of the poppet element 6014 thatare not exposed to the interior of the freezing cylinder 2500.

As will be appreciated from consideration of FIGS. 6C and 6D in light ofthe discussion provided above in connection with a self-cleaningelement, during a self-cleaning operation, cleaning and/or sanitizingfluid will be provided to the freezing cylinder such that all exposedsurfaces within the freezing cylinder 2500 (including all exposedsurfaces of the poppet element 2014 and any associated O-rings) will becleaned and sanitized. During that self-cleaning cycle the vent reliefassembly 6000 may be repeatedly activated, which may result incleaning/sanitizing fluid passing from the interior of the freezingcylinder, across portions of the vent relief assembly 6000 and out thefront of the faceplate to atmosphere or through the vent flush passage3056, and into the drain. In addition to this incidental cleaning,portions of the vent relief assembly 6000 may also be flushed throughactivation of the vent flush valve 2208 which may cause water to flowthrough the passage 3054, across elements of the vent relief assembly6000, and into the drain.

In certain embodiments, the vent purge valve 2034 may be activatedduring all, a portion, or repeated portions of any incidental cleaningor any flushing period to both inject gas into the flush passage 3056(thus impacting fluid flow) and cause movement of the piston 6004 (andmovement of the poppet element 6014).

It will be appreciated from above discussion that not all of thesurfaces of the vent relief assembly 6000 are exposed to the interior ofthe freezing chamber 2500 and that sanitizing of such non-productcontact surfaces may be unnecessary. As such, in the above-describedembodiments, the water from the water supply (as controlled by ventflush valve 2208) is used for the flushing operation described above.Alternate embodiments are envisioned where alternate fluid connectionsare made such that the fluid used for the flushing operation is the samecleaning and/or sanitizing fluid used for the cleaning and/or sanitizingof the freezing-cylinder.

As the above discussion indicated, in the described exemplary embodimenttwo areas of the system are refrigerated, namely the freezing cylinder2500 and the refrigerated ingredient storage compartment 2600. Aspectsof structures associated with one exemplary refrigeration storagecompartment 2600 are illustrated in FIG. 1A and FIGS. 7A-7E.

Referring first to FIG. 1A, the exemplary refrigerated ingredientstorage compartment (sometimes referred to herein in shorthand as the“refrigeration compartment”) is positioned approximately within themiddle ⅓ of the overall system and is accessible through ahinged-mounted and insulated door 1020 to which an affixed or removabledrip tray 1025 may be attached. Although not illustrated in FIG. 1A, therefrigerator door may include or be coupled to suitable gasketingmaterial and a thermal break to form a tight seal between the outerportions of the inner door surface and the outer portions of therefrigeration compartment.

FIGS. 7A-7E illustrate aspects of an exemplary refrigeration ingredientstorage compartment 2600 with the hinged door 1020 removed. As generallyillustrated in FIGS. 7A-7E, the ingredient refrigeration compartment maytake the form of a cabinet containing the refrigeration componentsdescribed herein that is surrounded by insulating material (e.g., denseinsulating foam or other suitable material) and paneling. In theillustrated embodiment, the refrigeration compartment 2600 includes anoverall structure that may include inner panel elements forming theinterior walls of the refrigeration compartment, outer panel elementsforming the exterior walls of the refrigeration compartment, andinsulation positioned between the interior and exterior panel elements.These elements may all be positioned within the overall structuralelements that form the overall product formation and dispensing system.

To increase the thermal isolation of the ingredient refrigerationcompartment, the compartment's components may be separated from theframe on which it is positioned by mounts or spacers which may bedesigned to minimize the extent of thermal conductivity between therefrigeration cabinet and the remainder of the system. Such mounts orspacers may be located on all, or fewer than all, sides of therefrigeration cabinet.

FIG. 7B illustrates the exemplary refrigeration compartment of FIG. 7Awith one of the sides of the compartment rendered transparent. Asreflected in FIGS. 7A and 7B, the interior of the refrigerationcompartment contains a number of tray supports in the form of ridgesthat extend horizontally, essentially along the sides of therefrigeration compartment from front to back (only two of which 7010Aand 7010B are identified). These tray supports are configured to supporta plurality of removable ingredient storage trays, one of which isidentified as element 7020 and—in the illustrated example—support themsuch that they are maintained in a configuration with a generallyforward tilting slope to facilitate maximum drainage of the ingredientscontained within the trays. As reflected in the FIG. 7B, each ingredienttray is removable from the refrigeration compartment for cleaning andreplacement and/or for easy positioning of an ingredient supply withinthe tray.

As reflected in in FIG. 7B, the exemplary ingredient storage tray 7020includes a main body having a pan-like structure that defines adispensing port 7025 on one end, where the pan-like structure and thedispensing port 7025 are designed to receive an ingredient supply unitin the form of a bag containing a liquid ingredient that is connected toa sterile coupling.

The ingredients may be supplied from any suitable supply apparatus. Inone embodiment, the supply apparatus may take the form of a bag-likecontainer that is coupled to a connecting port that is designed to matewith a connector coupled to the appropriate input line for the system.Such an embodiment is reflected in FIG. 7D-2 where a suitable bagconnection port 7500 is shown (the associated bag is not illustrated)along with an appropriate mating connector 7502. Forms of connectionother than the one shown in FIG. 7D-2 can be used to couple ingredientlines (or any other fluid containing lines) in the disclosed system. Forexample, a sanitary connecting arrangement, such as the one depicted inFIG. 7D-3 can be used for such connections.

It should also be appreciated that the ingredients need not be suppliedfrom an apparatus containing a collapsible bag. For example, FIG. 7Fillustrates an ingredient supply apparatus that includes a rigid orsemi-rigid structure.

In the illustrated example described herein, there are features on thefaces of the ingredient storage trays which interact with the traysupports to counteract the effect of the generally forward tilting slopein which the trays are maintained such that the storage trays cannoteasily move from a desired position and remain in place within therefrigeration compartment.

In certain embodiments, the ingredient provided by the ingredient supplyunit may consist of or comprise a non-diluted, dairy-based solution thatmay be used to form soft-serve ice cream, shakes and/or smoothies. Ofnote, in such embodiments, proper operation of the system will notresult in any (or any meaningful) exposure of the stored ingredientswithin the bag to any atmospheric air. As such, assuming that theingredient material as supplied in the bag is suitable for humanconsumption (e.g., is a solution that was pasteurized prior to or withinthe bag) further pasteurization of the bag contents need not beperformed. Thus, if a given ingredient bag is coupled to the system andused for several days, the ingredient bag may not need to be pasteurizedas it will both be stored within the temperature-controlled environmentof the refrigeration chamber and coupled to a sealed system that is notopen to the external atmosphere. Note that the sealed system approach ofthe exemplary dispenser disclosed herein is thus significantly differentfrom conventional open hopper systems where the hopper contentstypically must be pasteurized or discarded on a regular—and sometimesdaily—basis.

Referring back to FIG. 7C. a side-view of the exemplary embodiment ofFIG. 7B with all of the ingredient storage trays removed is provided. Asthis figure reflects, in the illustrated embodiment, the interior of therefrigeration compartment contains—in addition to the componentsdiscussed above—a single row evaporator coil 7040 that extendssubstantially across the entirety of the rear surface of therefrigeration cabinet and a drip tray 7050 that may be positioned belowthe evaporator coil and that may be configured to collect condensatedrippings that collect and fall from the evaporator coil 7040. As FIG.4C also illustrates, the refrigeration cabinet in the illustratedexemplary embodiment may also include an evaporator fan 7060; an airshroud 7065; a pump cover 7070; and a front panel 7075.

In the illustrated embodiment the evaporator fan 7060 is positionedwithin a location towards the middle front portion of the air shroud7065 such that activation of the fan will pull air generally from thefront of the refrigeration cabinet, up through the fan 7060 and into anair chamber defined by the air shroud 7065 and force air to flow downover the evaporator coil 7040 and out into the interior of therefrigeration compartment. Thus, activation of the fan 7060 will resultin the circulation of air within the refrigeration compartment andacross the evaporator coil 7040. Alternate embodiments are envisionedwherein the air flow direction is reversed such that flowing air wouldbe pulled through and over the evaporation coil before passing into therefrigeration compartment.

In the illustrated embodiment the evaporator fan 7060 is designed andconfigured to operate in response to signals provided by a controller(discussed below) on an ON/OFF basis and at a constant speed. Alternateembodiments are envisioned, however, where the speed of the evaporatorfan may be variable and controlled based on, for example, the differencebetween the temperature within the product refrigeration cabinet and adesired set point temperature, and/or on the time since the lastactivation of the evaporator fan.

In one embodiment the evaporator fan 7060 is configured through the useof switching elements to be energized and run anytime the refrigeratordoor is closed. In this embodiment, airflow will be provided throughoutthe product refrigeration cabinet regardless of the temperature withinthe cabinet. In alternative embodiments, the evaporator fan may be runbased on the differential between the detected temperature within theproduct refrigeration cabinet and a desired setpoint temperature and/oron a timed or pulsed basis to ensure that there are no lengthy periodsover which the fan is not operated. Such an embodiment may ensure atleast minimal air circulation within the product refrigeration cabinet.Still further embodiments are envisioned wherein the evaporator fan isoperated at a given speed (or turned off) whenever the refrigerationdoor is open to try to minimize any temperature increase that may occurthrough the opening of the door or the introduction of a non-chilledingredient supply unit into the refrigeration cabinet.

As described in more detail below, a number of components are positionedbelow the pump cover 7070 yet within the refrigeration cabinet such thatthe components are cooled within the refrigeration cabinet. In theexemplary embodiments, these components include a self-cleaningreceiving port 7800 (that corresponds with the system connection port2610 discussed above in connection with FIGS. 2A-2C); a peristaltic pump7300 (that corresponds to the pump 2300 discussed above); and an aircheck valve 7318 that controls the injection of gas into the fluidoutput line from the pump 7300.

FIG. 7D-1 illustrates an expanded, angled view of the front panel 7075and the self-cleaning receiver port 7800 (which is depicted as aspecific exemplary embodiment of the self-cleaning port 2800 discussedabove). As reflected in the exemplary figure, the self-cleaning receiverport 7800 is positioned along an angled surface of the front panel 7075.In the figure, the front panel 7075 also defines an opening throughwhich a hose element may pass. As reflected in FIG. 7D-2 , the hoseelement may include at its distal end a connecting element 7080. In theexemplary embodiment, the connecting element 7080 is configured so thatit may make connection with either the self-cleaning receiver port 7800or a dispensing port 7500 of an ingredient supply unit (e.g., as shownin FIG. 7D-2 ).

As FIG. 7D-1 shows, the self-cleaning receiver port 7800 port includes afirst, generally ring-like structure, that defines a connection port anda movable locking member or clamp 7805 that may be rotated between afirst position that permits the placement of a connecting element untothe connection port; and a second position that may be used to hold aconnecting element positioned within the connection port in place. Thelocking clamp may be constrained in the second position by, for example,a screw, latch or other element, to maintain the locking member inplace. Alternatively, the clamp may be oriented such that gravitationalforces alone keep the locking member 7805 in place. Although notspecifically illustrated in FIG. 7D-1 , a sensor or switch element (suchas a microswitch or a magnetic switch) may be used to detect when thelocking clamp is in the second (or locked) position and/or when aconnection element (such as 7080 as shown in FIG. 7D-2 ) is properlypositioned within the port 7800. This may be accomplished, for example,through the use of a magnetic element positioned within the lockingclamp or the connecting element.

Considering the discussion provided above in connection with FIGS.2A-2C, it may be appreciated that the disclosed dispenser system may beconfigured to be placed in the product formation and dispenseconfiguration or the self-cleaning configuration based on thepositioning of the connecting element 7080. For example, when theconnecting element 7080 is coupled to the dispense port of an ingredientbag, the dispenser will be in the product formation and dispenseconfiguration as schematically shown in FIG. 2B. When the connectingelement 7080 is coupled to the self-cleaning receiver port 7800, on theother hand, the dispensing system may be partially placed in theself-cleaning configuration as schematically reflected in FIG. 2C. Tocompletely place the dispensing system into the self-cleaningconfiguration, a blocking member in the form of a blocking cap 4500 mustbe affixed to the dispense spout of the faceplate 3008. Such positioningof the blocking cap 4500 will—as described above—enable fluid to flowfrom the dispense portion of the faceplate into the bypass passage 3900and, thus, enable the disclosed system to perform a self-cleaningoperation as describe above.

As further reflected in FIG. 7D-1 , the interior portion of therefrigeration cabinet defines a relatively flat floor section 7090 thatextends from the front opening of the cabinet and (in the illustratedexample, is sloped from back to front) in which is positioned a cleanertank spout 9030. As discussed in more detail below, the cleaner tankspout 9030 and the self-cleaning receiving port 7800 may be involved inan exemplary self-cleaning operation. (Notably, in the describedexample, both the self-cleaning receiver port 7800 and the cleaner tankspout 9030 are positioned within the refrigeration cabinet, 2600 suchthat the refrigeration cabinet door 1020 must be opened to access theport and/or the spout 9030.)

In the illustrated example, the cleaner tank spout 9030 is used topermit the placement of a cleaning or sanitizing product into a cleanertank structure (discussed in more detail below). The positioning of thecleaner tank spout 9030 (and the cleaner tank structure) physicallybelow the ingredient storage trays 7020 minimizes the possibility thatany cleaning sanitation products will find their way into the ingredienttrays (or be mixed with any content in the trays).

Although not separately illustrated herein, embodiments of the describedingredient refrigeration cabinet 2600 are envisioned wherein the door tothe cabinet is associated with a locking element that can be activatedto lock the door and prevent access to the interior of the cabinet 2600and/or lock out any dispensing of product within the freezing cylinderupon the detection of certain conditions warranting a lock-out. Forexample, in certain embodiments the controller may receive an indicationif the detected temperature within the refrigeration compartment isdetermined to be within an undesired range (e.g., above a certaintemperature level) for an undesired period of time, and lock the systemout (e.g., prevent the dispensing of product) if such a condition isdetected. Additionally—or alternately—the lock-out system could monitorthe frequency at which the product ingredient supply bags are changedout and lock the system out in the event that a bag is not changedwithin a determined period. Still further, the lockout system couldmonitor the frequency at which the self-cleaning feature of the systemis activated (as discussed in more detail below) and lock the system outin the event that the system is not subjected to self-cleaning within anacceptable period of time since the last cleaning.

In embodiments that include a lock-out system the controller may beprogramed to provide a visual indication that the system is locked out,an indication of the reason for the lock-out, and instructions on howthe system can be reset and the lock-out condition removed.

In the exemplary embodiment of FIGS. 7A-7E, a substantial number of thesystem components that will come in contact with any food ingredientsare positioned within the refrigerated compartment such that they aremaintained at a controlled temperature level. Such components mayinclude but are not limited to the ingredient supply elements; theconnection element 7080 the pump 7300; the air check valve 7318; and thefluid connections between those components. One exemplary approach andarrangement for positioning such components within the refrigerationcompartment is provided in FIG. 7E which shows a downward-looking viewtowards the bottom of the refrigeration compartment 2600 with the cover7070 removed.

One of the benefits of the particular arrangement depicted in FIG. 7E isthat the use of the pump cover 7070 within the refrigeration chamber2600 may provide both a protective barrier to prevent any potentiallyspilled ingredient within the refrigeration compartment from directlycontacting any of the described components and it provides a structurethat may be easily removed to permit direct access to the describedcomponents for any required maintenance.

As reflected FIG. 7E, the pump 7300 may be positioned on the floor ofthe refrigeration cabinet 7600 and may be configured such that its inputis fluidly connected to a hose element coupled to the connecting element7080 (not shown in FIG. 7E). In such an arrangement, operation of thepump will pump fluid through the connecting element 7080 into thesystem. When the connecting element 7080 is coupled to an ingredientsupply element, the pumped fluid will be the ingredient. When theconnecting element is coupled to the self-cleaning port 7800, the pumpedfluid may be comprised of water, a mixture of water and cleaning and/orsanitizing fluid, or only cleaning and/or sanitizing fluid. The pump maytake any suitable form and, in one embodiment may take the form of apositive displacement driven pump, such as a rotary peristaltic pump.Such a pump may be driven by an electrically actuated motor (not visiblein the provided figures).

As described above, in the disclosed system the output from the pump7300 (which will typically be a fluid output) is combined withpressurized gas such as air or another pressurized gas, which may beprovided through activation of the gas control valve 2016 (discussedabove in connection with FIGS. 2A-2C).

The combining of a fluid output from the pump 7300 and the pressurizedgas may be accomplished in various ways. In the example of FIG. 7E, thecombination of fluid from the pump 7300 and pressurized gas isaccomplished through the use of a novel pressure block assembly 7020that defines a first input 7021 for receiving the fluid output from theperistaltic pump, a second input 7022 for receiving a pressurized gas(which may be received from the output of the gas control valve 7016,discussed above in connection with FIGS. 2A-2C) and an output 7023 fromwhich will typically flow a solution comprising a mixture of the fluidfrom the pump 7300 and the pressurized gas from the (or one of aplurality) gas source to provide a gas/ingredient mixture that will beprovided to the freezing cylinder.

In certain embodiments a pressure transducer (not labeled in FIG. 7E)may be used to provide the pressure at the output of the pressure blockassembly 7020.

In the example of FIG. 7 , a temperature measuring thermistor 7060 isalso positioned below the pump cover to provide an indication of thetemperature within the refrigeration compartment.

FIGS. 8A-8E-2 illustrate details of exemplary embodiments of a pressureblock assembly 8020 that may be used as the pressure block assembly 7020of FIG. 7E.

FIG. 8A provides a partial isometric view of the exemplary pressureblock assembly 8020. As depicted in the figure, the exemplary assemblyincludes a main block element 8060 which may take the form of a block ofsuitable material (e.g., metal, or a plastic or resin component, or acomposite) in which are formed the openings, passages and featuresrequired for proper operation of the block. Positioned within theexemplary block in the exemplary embodiment is a fluid input connectionbarb assembly 8021 for receiving the fluid output from the pump 7300.The fluid input connection barb assembly 8021 may include: (a) acheck-valve, for ensuring that there is no back-flow from the assembly8020 into the pump 7300, and suitable O-ring elements (and O-ringreceiving features) to ensure a proper seal between the fluid inputconnection barb assembly 8021 and the main block element 8060.

An output connection barb assembly 8023 is also provided in the exampleof FIG. 8A for providing an output connection from the assembly 8020. Inthe illustrated example, no check valve is illustrated or necessarilyrequired for the output connection barb assembly 8023.

In the example under discussion, a gas input assembly 8022 is providedthat includes a check-valve (discussed in more detail below) forreceiving pressurized gas.

A pressure transducer 8062 is coupled to the body 8060 to detect thepressure within the body at a point where the fluid received at thefluid input has been mixed with the gas received at the gas input. Thispressure measurement may be provided to a controller and may bemonitored to provide information concerning the operation of the system.For example, during a period when the dispenser is operating in aproduct formation and dispensing configuration, the pressure signal fromthe pressure transducer 8062 may be monitored to determine whether aproduct ingredient supply element is empty (as a low-pressure conditionwould be associated with an empty supply element). Additionally, oralternatively, the presence of an unexpectedly low pressure couldindicate that certain connections necessary for proper system operation(e.g., a connection of the system input connector 2610 to theself-cleanings port 2800) were not appropriately made or have comeloose.

Still further, because the junction at point 8063 is fluidly coupled tothe interior of the freezing cylinder 2500, the pressure detected at thejunction 8063 by transducer 8062 may be used to infer the pressurewithin the freezing cylinder 2500. As discussed elsewhere herein, thisdetected pressure may then be used to determine whether activation of acylinder vent relief assembly is necessary to drop the pressure withinthe cylinder 2500.

FIG. 8B provides a cross-section view of the example of FIG. 8A with thesection taken along a plane passing roughly at the midpoint between thetop of the assembly (where the top of the pressure transducer 8062 islocated) and the bottom of the assembly.

As reflected in FIG. 8B, the block 8060 defines a first opening thatreceives the fluid input assembly 8021 that is fluidly coupled to afirst passageway that feeds to a central space (i.e., a junction pointor passage) 8063. The block 8060 further defines a second receivingopening for receiving the gas input assembly 8022 that is fluidlycoupled to a second passageway that is also fluidly coupled to centralspace 8063. The block further defines a third receiving opening forreceiving the output assembly 8023 and a third passageway that couplesthe central space 8063 to the output assembly 8023. As will be apparentfrom FIG. 8B, during operation, fluid may be pumped into the blockassembly 8060 by the pump 7300 into the central space 8063 where it maybe mixed with gas from the pressurized gas supply, and the mixedgas-fluid mixture may be forced through pressure produced by the pump7300, gas pressure and/or a combination of both, out of the outputassembly 8023 and (although not illustrated in the figures underdiscussion) into the freezing cylinder of the system.

For purposes of ensuring proper operation and self-cleaning, the gasinput assembly 8022 of the illustrated embodiment has a configurationthat promotes cleaning efficiency. Details of this design are reflectedin FIGS. 8C and 8D.

Referring to FIGS. 8C and 8D, it may be seen that the air input assembly8022 includes a gas fitting elbow 8064, coupled to a main air check body8065. A sealing compression ring 8066 is positioned external to the mainair check body 8065. A portion of an air check poppet 8067 passesthrough an opening in the air check body 8065 and a poppet sealingO-ring 8068 is positioned around an external portion of the poppet 8067.A spring element 8069 is positioned within the main body 8065 and servesto bias the air check poppet 8069 in a closed position against the mainbody 8065.

As these images show, the portion of the air input assembly 8022 that isexposed to the inner space 8063 where the input fluid and the input gasmix is both limited and of a relatively simple geometry in that itcomprises the upper flat surface of the housing 8065, the poppet sealingO-ring 8068, and a small portion of the poppet 8067. As these figuresalso show the exposed portions are of a relatively simple geometry withno hidden pockets where material could be retained. Because of thisconfiguration, when cleaning and/or sanitizing solution is pumpedthrough the system as part of a self-cleaning operation, all componentsof the air check valve that come into contact with food product and/oringredients used to form food product will be adequately cleaned andsanitized.

In the example of FIG. 8A-8D, the compression ring 8066 takes the formof a flat gasket washer. The use of a flat gasket washer helps preventcrevices that could be difficult to clean and further ensures a strongseal that will prevent any backflow.

In the examples of FIG. 8A-8D (and other examples set forth herein inwhich separate O-rings or compression structures are described) itshould be understood that any separate structures could be formedthrough an over-molding process as elements integral with the elementsto which the O-rings are attached.

In addition to promoting the effectiveness of cleaning and sanitizingoperations, the configuration of the block assembly 8020 provides for asingle component that may be readily replaced should any aspects of theoverall assembly fail or require replacement for any other reason.

It should be appreciated that the embodiment of FIGS. 8A-8D areexemplary only and that other forms of components and, in particular,air-check valves may be used without departing from the teachings ofthis disclosure. For example, FIGS. 8E-1 and 8E-2 depict an alternateembodiment of an alternative air input assembly 8522 that may be used inconnection with an embodiment like that described in FIGS. 8A-8D whereit is positioned in a block that also receives a fluid input, or inconnection with a stand-alone application, where the pressurized gas isinjected into a line feeding the freezing cylinder through anindependent connection (e.g., one that does not involve a common block).

As reflected in FIGS. 8E-1 and 8E-2 , the alternate air input assembly8522 includes an elbow connection 8564, a main body 8565, and air checkpoppet 8567. A spring element 8569 is provided to bias the air checkpoppet in a closed position. In the illustrated example, the air checkpoppet 8567 defines a main central passageway through its interior thatis fluidly coupled to the gas inlet from the elbow connection 8564 andone or more passageways that permit the passage of gas from the maincentral passage to the exterior of the poppet 8567. As shown in thefigure, a portion of the poppet 8567 passes outside of the main body8565, and an O-ring 8572 is attached to the poppet 8567 external to themain air body. In the example of FIGS. 8E-1 and 8E-2 , the main valvebody 8565 defines a recess in which the O-ring 8572 may be received.

FIG. 8E-1 illustrates alternative air-check valve assembly 8522 in aclosed position. As will be seen in this example, the O-ring 8572 sealsagainst the main valve body 8565 and the pressure from the springelement 8569 within the main valve body tends to maintain the air checkassembly in the closed position.

FIG. 8E-2 illustrates the alternative air check valve when pressurizedgas is provided at the input of the elbow connection 8565 thepressurized gas acting on the surface of the poppet 8567 overcomes theforce of the spring element and drives the valve open.

In the example of FIGS. 8E-1 and 8E-2 , the entirety of the air checkvalve assembly 8564 may be held in place through a variety of differentapproaches suitable for holding the assembly 8564 securely in place andenergizing the seal 8066. For example, in one embodiment, a press-fitsealing arrangement may be used in which the air-check assembly 8522 ispositioned within a recess defined by the block and in which theair-check assembly is held in place by virtue of the compressive forcesprovided by a sealing O-ring 8580. Alternative approaches are envisionedin which mechanical fastening approaches—such as an approach usingscrews and/or a snap ring—are used to maintain the appropriate forces onthe seal 8066 and maintain the proper positioning of the entirety of theair check valve assembly 8564. A benefit of the approaches discussedabove is that they allow for easy and rapid removal and replacement ofthe air-check valve. In applications of the present dispensing systemwhere extreme sanitary conditions must be maintained (e.g., in a healthtreatment environment) the alternative air check assembly 8564 of FIGS.8E-1 and 8E-2 may be easily removed and replaced at each cleaning cyclefor the dispensing assembly or on an alternate schedule (e.g., everyfifth cleaning cycle, every other month, or upon a change in theprovided product or the anticipated consumer for the dispensed product).

As will be appreciated from those having the benefit of this disclosure,through the use of the pressure block assembly 8020, and/or thecontrollable vent relief assembly 6000, the exemplary disclosurediscussed herein allows for dynamic control of the pressure within thefreezing cylinder 2500. The ability to control the pressure within thecylinder 2500 enables the disclosed dispenser to process a wide varietyof ingredients and food products. Moreover, because of the unique natureof the pressure block assembly 8020 and the vent relief valve positionedwithin the faceplate, the disclosed dispenser allows adjustment of thecylinder pressure through the injection of pressurized gas alone intothe cylinder (through operation of the gas supply valve 2016), throughthe injection of fluid alone (through operation of the pump 7300); andthrough injection of a gas/fluid mix. The ability to dynamically, and ina controlled manner, inject pressurized gas alone into the freezingcylinder (without any fluid product) or to inject fluid alone (withoutany intermixed gas) greatly expands the operating characteristics of thedisclosed dispenser.

In addition, the disclosed dispenser is capable of generating a suitableproduct upon a “first freeze” of the product. This can be done through amulti-step process wherein, in a first step, the system initially fillsthe freezing cylinder with liquid ingredient only (e.g., throughactivation of the pump 7300 during conditions where no gas is mixed intothe pumped ingredient) while at the same time operating the vent reliefassembly 6000 to avoid a pressure buildup in the cylinder and, at thesame, time NOT operating the auger (such that no gas is mixed into theliquid in the cylinder during this initial filing step). This first stepcan be terminated once it has been determined or inferred that a desiredamount of liquid ingredient has been pumped into the cylinder. Once thisinitial fill is done the system can proceed to a second step, whereinpressurized gas (or air) is injected into the system until the cylinderpressure reaches a desired level. In a third step (which can beginafter, during, or co-incident with the second step) the auger can beactivated to begin processing the material in the cylinder. The resultof the described first freeze process is a product that will tend tohave the same quality and consistency as product typically formed aftera dispenser has been operating for an appreciable amount of time. Aswill be appreciated by those having the benefit of this disclosurealternative methods and sequences of control can be executed to achievebenefits enabled by the use of non-air gasses. For example, if non-airgasses are used, the sequence could include a first step in which thefreezing cylinder and all or some of the passages within the system arefilled with the non-air gas while the vent is open to displace all “air”from the system. In such an embodiment, the system can be substantiallyor entirely purged of all “air” such that only the desired non-air gasis used for product creation or dispensing.

As described above in connection with FIG. 2A, during the self-cleaningoperation, operation of the pump 7300 may be used to pull cleaningand/or sanitizing solution from a cleaner supply element 2820.

The cleaner supply element 2820 may take many different forms includinga replaceable cartridge element containing a cleaning and/or sanitizingsolution, a bag of cleaning and/or sanitizing solution and/or a storagetank in which cleaning and/or sanitizing solution may be added. Thecleaning and/or sanitizing material provided to cleaner supply element2820 may take any suitable form, and may be, a liquid cleaner similar tothe type used for cleaning dairy milking and bottling equipment.

In the exemplary embodiment discussed above, the cleaner supply element2820 may take the form of a tank coupled to a cleaner-receiving spout.Examples of such a cleaner supply element 2820 are depicted in FIGS.9A-9D.

FIG. 9A provides a partially orthogonal view of an exemplary cleanersupply element 9000 that includes a storage tank 9002, a piercingreceiving spout 9030, and a sleeve element 9006. As reflected in FIG.9A, the tank defines an outlet element 9008 that may feed via a hose toa manifold that houses the cleaner solenoid 2818 (discussed above inconnection with FIG. 2A). Such a coupling of the cleaning agent storagetank 9002 and a separate cleaning agent solenoid 2818 providesflexibility in the positioning of the tank 8002 and the solenoid 2818since they can be positioned independent of each other.

FIG. 9B illustrates an alternate version of the structure shown in FIG.9A with the sleeve element 9006 hidden and the piercing receiving spout9030 separated from the storage tank 9002.

In operation of a system utilizing the cleaner supply element 9000described above, a source of cleaning and/or sanitizing material (suchas a container with a foil lid structure) may be aligned with thecleaner supply element 9000 such that the foil lid of the container isaligned with the piercing/receiving spout 9030. The foil lid may then becompressed against the piercing/receiving spout 9030, such that thespout pierces the foil lid, thus allowing the cleaning and/or sanitizingmaterial to flow from the supply into the tank 9002. Once in the tank9002, the cleaning and/or sanitizing materials are available for use ina self-cleaning operation as described above. The cleaning and/orsanitizing material may take the form of a liquid material, a solidmaterial (in granular, pellet or other form), or a mixed liquid/solidmaterial.

The cleaner supply element of FIGS. 9A and 9B is exemplary. Alternateembodiments are envisioned, including embodiments that include a capstructure and/or a float switch positioned within the tank 9002 toconfirm the presence of a suitable amount of cleaning agent prior to theinitiation of a self-cleaning operation. One such embodiment is depictedin FIG. 9C.

The embodiment of FIG. 9C is generally similar to the embodiment ofFIGS. 9A and 9B with the primary differences being the inclusion of aflip-off cap 9032 and a float switch 9040. The float switch 9040 may becoupled to a system controller to provide an indication of whether asufficient amount of cleaning agent is detected within the reservoir9002. The output from the float switch 9040 may also be used to verifythat the cleaning agent is being pumped out of the reservoir 9002 duringa self-cleaning operation.

In the exemplary embodiments of FIGS. 9A-9C, the cross-section of thestorage tank 9002 may be generally rectangular and the tank 9002 iscoupled to the cleaning agent solenoid 2818 through a hose connection.Alternative embodiments are envisioned wherein the structure for storageof the cleaning agent has a generally circular cross-section and/orwhere the cleaning agent solenoid valve 2818 is formed in an integratedmanner with the cleaning agent storage reservoir. One such alternativestructure is generally depicted in FIG. 9D.

Referring to FIG. 9D a generally cylindrical reservoir element 9102 isprovided that defines a relatively cylindrical storage space that has anopen upper portion and a sloped lower portion. The sloped low sectionfeeds into a junction area 9120 that is coupled to receive fluid passingfrom a fluid inlet 9122 to a fluid outlet 9124. A plunger element from asolenoid valve 9104 (that may be used as the cleaner solenoid 2818 inFIG. 2C) is provided that, in its normal un-activated position, extendsinto the junction area 9120 and prevents the flow of solution from thereservoir or from the fluid inlet to the fluid outlet. Activation of thesolenoid valve, however, will cause the plunger element of solenoid 9104to move to an open position such that solution from the reservoir mayflow into the junction area and fluid may flow from the fluid inlet tothe junction area where it may be mixed with cleaning agent, and thefluid/cleaning agent mix may flow out of the fluid outlet.

In the illustrated example, a cap-structure 9106 with a check-valveelement 9108 is also provided that may be removed (e.g., by unscrewingand removing it) to permit the introduction of cleaning agent into thereservoir and that may be positioned (e.g., by screwing) to close outthe reservoir during other operating intervals. The check-valve element8108 will allow air to be sucked into the interior tank reservoir 9102,thus facilitating evacuation of the cleaning agent solution from thetank.

The general operation of the cleaning supply elements discussed abovewill hereafter be described. At an appropriate time, an operator of thesystem can place cleaning agent material into the cleaning agentreservoir by, for example tearing open a pouch of cleaner or by usingthe piercing-receiving element to pierce the lid of a cleaning agentcontainer. At a later time, the cleaner solenoid valve 2818 may beactivated to enable fluid connection between the tank and the remainderof the self-cleaning system. Under such conditions, activation of thepump 7300 which is “downstream” of the tank, will create a partialvacuum that will tend to pull the cleaning agent solution from the tankinto the remainder of the self-cleaning system. It should be noted thatin embodiments where the cleaning agent reservoir is not sealed from theexterior atmosphere (e.g., by a screw-on cap with a check-valve) it willbe desirable to turn on the pump 7300 before the cleaning agent solenoid2818 is activated to ensure that a negative pressure exists within thestorage reservoir at the time the solenoid 2818 is opened. In otherwords, the operation of the pump creates a pressure differential betweenacross the fluid in the tank (e.g., a differential between atmosphericpressure operating against one surface of the cleaning fluid and therelative vacuum created by the pump operating against the othersurface). Otherwise, there is the potential that positive pressure atthe output of the storage reservoir could cause some backfill. Incertain embodiments additional control schema may be implanted toprovide for a controlled backfill of the reservoir to provide a rinsingfunction for the cleaner supply tank. During such an operation, the tankwould first be partially or completely drained as described above.Then—with the drain valve 2816 closed, the pump 2300 OFF, and thedispense valve in the OFF position—the water fill valve 2808 may beopened resulting on the backfilling of the tank with water. Under suchcircumstances, the float switch 9040 can be used to sense the fluidlevel within the tank. Once the desired state change has been detected,the water fill valve 2808 can be turned off and the tank drained asdescribed previously. This tank cleaning operation can be repeated asnecessary and may be implanted in such a manner that the tank cleaningoperation is implemented is performed each time a system self-cleaningoperation is performed, once per a given number of system self-cleaningoperations (e.g., every third system self-cleaning operation), or uponrequest by a user.

The use of a cleaner reservoir or tank as illustrated above withpackages or small containers of an amount of cleaning agent sufficientfor a single self-cleaning operation is exemplary. Alternate embodimentsare envisioned wherein the cleaning agent is supplied in a largebag-in-box container that contains sufficient cleaning agent formultiple self-cleaning operating cycles. Still further embodiments areenvisioned wherein the cleaning agent is provided through means of asmall, single use, flexible pouch with a rigid connector. In such anembodiment, the user of the system could connect the rigid connector toa receiving port provided by the self-cleaning system and the systemcould then evacuate the contents of the pouch in a manner similar tothat described above in connection with the evacuation of tank. The useof a bag-in-box container, or a flexible pouch container, arepotentially beneficial in that they tend to minimize the potential foran operator spilling or coming into contact with the cleaning agent.Moreover, such embodiments may utilize flexible packaging for thecleaning agent, and vents or check valves (for sucking air) may not berequired for efficient evacuation of the cleaning agent from theprovided packaging.

Of note, the piercing receiving spout 9030 described in connection withFIGS. 9A and 9B may be positioned such that it extends into therefrigeration cabinet 2600 (as generally depicted in FIG. 7D-1 above).In such embodiments, the preparatory steps to the initiation of aself-cleaning operation may involve opening the refrigeration door, andthen—in no specific order—(a) moving the connecting element from oneconfiguration where it is coupled to an ingredient bag port to anorientation where it is coupled to the self-cleaning connection port and(b) placing cleaning and/or sanitizing materials into the tank.

As the above discussion reveals, the disclosed system includes twocomponents that are actively refrigerated, specifically the refrigeratedingredient storage compartment 2600 and the freezing cylinder 2500.FIGS. 10A-10C illustrate aspects of exemplary refrigeration sub-systemfor performing these functions.

Referring to FIG. 10A, select components in exemplary refrigerationsub-system 100 for use within the overall system are shown. Therefrigeration sub-system 100 depicted in FIG. 10A. performs at least twodistinct cooling/refrigeration/freezing functions. First, therefrigeration sub-system 100 operates to maintain the temperature withinthe refrigerated ingredient storage compartment 2600 within a desiredrange. Second, the refrigeration sub-system 100 operates to control thetemperature within the freezing cylinder 2500 to provide a dispensablefood product having certain desired properties.

As reflected in FIG. 10A, the illustrated exemplary refrigerationsub-system comprises a first compressor 205 and a second compressor 105.In the illustrated example, the compressors may be of differing sizeswith the second compressor 205 having a larger capacity than the firstcompressor 105. The first compressor 105 may be fluidly coupled to afirst condenser 110 and the second compressor 205 is fluidly coupled toa second condenser 210. In the example of FIG. 10A, the second condenser210 is larger than the first condenser 110 and, the first condenser 110is physically positioned above the second condenser 210.

In the illustrated example, the first condenser 110 may be fluidlycoupled to an evaporator 130 that may comprise the evaporator positionedwithin the refrigerated ingredient storage cabinet 2600, discussedabove. In the example of FIG. 10A, the evaporator 130 takes the form ofa wall-line structure through which the fluid/gas carrying portions ofthe evaporator snake through in a generally serpentine pattern.

In the example, the second condenser 210 is fluidly coupled to anevaporator 230 that is positioned within the cold pack assemblycontaining the product freezing cylinder 2500 and positioned to cool thefreezing cylinder. In the example of FIG. 10A, the second evaporatorincludes a fluid/gas path that generally surrounds and encircles thefreezing cylinder.

As reflected in FIG. 10A, a single condenser fan 200 is provided that,when activated, causes air to flow across both the first condenser 110and the second condenser 210.

Although not depicted in FIG. 10A, the illustrated exemplaryrefrigeration sub-system also includes a controller that receivesvarious input signals from sensors within the dispensing system and thatprovides various output control signals to control various components ofthe dispenser, including components of the refrigeration system of FIG.10A.

For purposes of the present discussion, the exemplary input signals tothe controller may include but are not limited to a signal reflective ofthe temperature within the product storage refrigeration cabinet 2600,and/or signals reflective of conditions within the freezing cylinder2500. For purpose of the present discussion, the output control signalsprovided by the controller include at least signals to control theoperation of the compressor 105, the compressor 205, and the commoncondenser fan 200.

The general operation of the illustrated refrigeration system componentsassociated with controlling the temperature within the ingredientrefrigeration cabinet 2600 will be discussed first.

In the illustrated embodiment of FIG. 10A, the controller receives thesignal reflective of the temperature within the ingredient storagecabinet 2600. In the example, the controller is set at (or providedwith) a desired setpoint temperature (or range of temperatures) for theproduct storage refrigeration cabinet. For example, a desired range of33° F. on the low end and 38° F. on the high end could be programmedinto the controller and/or selected by a user or system operator duringsystem configuration. If the controller determines that the temperaturewithin the cabinet has exceeded the upper range setting (or has exceededa single setpoint by a given amount) the controller may activate thecompressor 105. Alternatively, if the controller determines that thetemperature within the cabinet is below the lower range setting (orbelow a single setpoint by a given amount) it may then either turn offthe compressor 105 or maintain the compressor in an off state if it isnot operating.

In certain embodiments, the controller may also be configured to operatethe condenser fan 200 in conjunction with the activation of the firstcompressor 105 and to de-activate the condenser fan 200 whenever thecompressor 105 is not operating. In other embodiments, in response tothe reception of signals warranting activation of the compressor 105,the controller may be configured to first activate the condenser fan 200for a given delay period of time (e.g., 5-10 seconds) if it is notalready activated, and then, after expiration of the delay period,activate the compressor 105. (Note that there may be no need to delayactivating the first compressor if the condenser fan is already runningat the time the controller receives signals warranting activating of thecompressor). In still other embodiments, the controller may operate thecondenser fan based on other parameters.

The controller may further be configured to deactivate the condenser fan200 once the conditions warranting activating the associated compressorare no longer present, and in the absence of other signals warrantingcontinued operation of the fan (e.g., continued operation of thefreezing chamber compressor).

In addition to the above situations, the controller within the exemplarysystem under discussion may be configured to operate the condenser fan200 under additional conditions unrelated to the operational state ofthe compressor 105 (or the compressor 205). For example, becauseexposure of any compressor to high heat may tend to reduce the usefullife of the compressor, embodiments of the illustrated system areenvisioned wherein the controller receives a signal from a temperaturesensor within the interior space within which the compressor 105 (andpotentially the compressor 205) is/are located and runs the condenserfan 200 to cool this interior space should the detected temperaturewithin the space rise above a certain level. The compressor orcompressors may also be run together or individually to maintainconditions within a pre-established range for a given period of time.

To avoid running the compressor 105 during conditions where thecondenser fan 200 has failed (a condition that could damage thecompressor) the controller may further be configured to receive a signalconfirming proper operation of the fan 200. For example, a tachometercould be coupled to the condenser fan 200 that would generate an outputabove a certain level if the fan was operating properly. Alternatively,the controller may receive an indication of the fan current such thatthe presence of fan current above a certain level would indicate properfan operation. Still further indications known to those skilled in theart may be used to detect proper fan operation. In any of the precedingexamples, the controller may be configured to deactivate the compressor105 (or any operating compressor) in the absence of proper fanoperation. If these conditions are met, the system controller may befurther configured to take further actions that may result in continuedoperation of the system, albeit at a reduced capacity, or to deactivatethe system. The system controller may also be configured to alert anoperator to these abnormal conditions.

In the example of FIG. 10A, the condenser fan 200 may be a single speedfan that is either activated or deactivated. Alternative embodiments areenvisioned where the fan 200 may be a variable or multi-speed fan thatcan be operated at different speeds based on different operatingconditions. For example, in embodiments (discussed in more detail below)in which the condenser fan 200 is operated when either the compressor105 or a the compressor 205 is to be activated, the controller may beconfigured to control the fan 200 to operate at one speed when one ofthe compressors is activated (e.g., only compressor 105), another speedwhen only the other of the compressor (e.g., compressor 205) isactivated, and yet at another speed if both compressors are activated atthe same time. It should be appreciated that the concept of avariable/multi-speed fan may be implemented either through a fan thatincludes a fan motor designed to operate at multiple speeds (e.g., amotor with different input power taps) or a fan motor that may beoperated at variable speeds based on the level of the current and/orvoltage and/or the frequency or duration of voltage pulses applied tothe fan motor.

In the exemplary embodiment of FIG. 10A, a fixed baffle may be used tocontrol and direct airflow caused by operation of the common condenserfan 200 across both the first 110 and the second condenser 210.Alternate embodiments are envisioned wherein an adjustable baffle may beused to control what portion of the airflow generated by the commoncondenser fan flows across the first condenser and what percentage flowsacross the second condenser. In such embodiments, the controller may beconfigured to adjust the positioning of the adjustable baffle based on avariety of inputs and conditions, such as, but not limited to: whetherone or both condensers are operating; the relative prioritization ofcooling the refrigeration cabinet interior versus freezing the interiorof the freezing cylinder; or any other suitable control strategies thatmay be envisioned by those in receipt of the disclosures containedherein. It will be appreciated that control of such a dynamic baffle mayadjust, and may be used to control or partially control, the headpressure (or discharge pressure) from the first and/or the secondarycompressors.

At a high level, the operation of the exemplary refrigeration system 100of FIG. 10A to control the temperature within the product freezingcylinder 2500 may be accomplished through an operation where compressedrefrigerant is provided from the second compressor 205 to a refrigerantfluid input feeding the evaporator encircling the freezing cylinder2500, circulation of the compressed refrigerant about, and evaporationof the refrigerant within the evaporator 230 associated with thefreezing cylinder 2500, and discharging the evaporated refrigerant froma refrigerant outlet.

Considering FIG. 10A in combination with FIG. 10B additional details ofthe described embodiment may be understood. As reflected in thesefigures, in the exemplary embodiment of FIGS. 10A and 10B, the first andsecond compressors 105 and 205 are both positioned at the bottom of thedescribed dispenser and within the lower one-third of the cabinetstructure supporting the dispenser. As shown more clearly in FIG. 10B,which provides a front view of the exemplary system (with variouscomponents hidden) substantially all of the first and the secondcompressors 105 and 205 are located on the same side of the dispenserwith respect to a vertical plane passing through the mid-point of thetop of the dispenser and extending from the front of the dispenser tothe rear of the dispenser. In this example, it will also be noted thatvarious components associated with the freezing cylinder 2500refrigeration system, such as the main expansion valve 246, an optionalgas-bypass valve 245, and an optional liquid injection or secondexpansion valve 255, are all located on the same side of the compressor(with reference to the plane discussed above) as the compressors 105 and205.

As further shown in FIGS. 10A and 10B, the first and second condensers110 and 210 may be of differing size and may be arranged such that thefirst condenser 110 is positioned substantially in the middle ⅓ of therear panel (and within the area associated with the rear panelhorizontal vents) and the second condenser 210 may be positionedsubstantially in the lower ⅓ of the system frame. This positioning mayprovide a low center of gravity for the system which promotes theoverall stability of the system.

As further reflected in FIGS. 10A-10B, the condenser fan 200 may bepositioned such that, when activated, it causes air to flow from theexterior of the system 1000, through an air inlet at the rear of thesystem, through the fan, then across the two compressors. Alternatively,the airflow could be into the interior of the system through the frontkick plate, past the first and the second condensers 110 and 210, and tothe exterior of the system through the vents in the rear panel. Of note,in the examples described above, each described airflow path directs airacross the first and second compressors 105 and 205 such that operationof the single condenser fan 200 serves the dual purpose of bothdirecting air across the condensers 110 and 210 and across the twocompressors 105 and 205.

In one exemplary embodiment of the refrigeration system 200 of FIGS.10A-10B, the expansion valve used to control the expansion of thecompressed refrigerant through one or both of the evaporators 130 and/or230 may take the form of a motorized stepper valve or a variablecontinuous expansion valve. In some embodiments, the expansion valve maytake the form of a valve whose open area may be variably controlledthrough a variable drive element, such as a stepper motor. One suchembodiment, in which a stepper-motor driven expansion valve is used tocontrol the injection of expanded compressed fluid into the evaporator230 within the cold pack assembly is depicted in FIG. 10C.

Referring to FIG. 10C, the cold pack assembly is illustrated withoutshowing the details of the freezing cylinder 2500 evaporator. As will beappreciated, the freezing cylinder 2500 evaporator can take any form.FIG. 10C does illustrate, however, the refrigerant inlet 247 and outlet248 lines feeding into and out of the cold pack assembly.

As depicted in FIG. 10C, a stepper-motor driven variable expansion valve246 is located upstream of the refrigerant inlet 247. As will beappreciated, the open area of the variable expansion valve 246 can becontrolled dynamically such that the amount of refrigerant flowing intothe evaporator 230 can be controlled. This can be controlled through adirect adjustment of the open area of the valve 246 or through operationof the valve 246 in a pulse width modulated mode (or a pulse frequencymodulated mode) wherein the valve 246 is alternately open and closed inaccordance with a variable duty cycle, for fixed duration pluses at avariable frequency or a combination of pulse width and pulse frequencycontrol.

By controlling the extent to which refrigerant is provided to theevaporator 230, the cooling/freezing characteristics of the freezingcylinder 2500 may be configured and adjusted. This adjustability is oneof many aspects that are important in the present dispenser because itallows the freezing cylinder refrigeration system to be adapted to avariety of different food products. Thus, for example, through propercontrol of the variable control valve 246, the characteristics of thefreezing cylinder 2500 may be adjusted to be optimized for thedispensing of soft-serve ice cream, a shake product, a smoothie produceand/or a food product having a specific desired consistency. Inparticular, the evaporator capacity of the evaporator 230 (and/or 130)may be controlled and adjusted through control of the control valve 246.

In addition to using a controlled variable expansion valve 246 (or as analternative) the capacity of the evaporator 230—and thus the freezingcharacteristics of the freezing cylinder 2500—may be controlled throughthe use of an additional controlled expansion valve, such as theadditional controlled expansion valve 255 shown in FIGS. 10C-10D. Theadditional controlled expansion valve 255 may take the form of anysuitable controlled expansion valve that may be either turned ON and OFFor that may be dynamically controlled (through discrete adjustment ofthe valve's open area, through pulse with or pulse frequency modulation,or any other suitable control scheme). As shown in FIGS. 10C-10D, theadditional controlled expansion valve 255 is located “upstream” of theexpansion valve 246 with respect to the flow of refrigerant into theevaporator 230.

Operation of the additional controlled expansion valve 255 will resultin a portion of the refrigerant flowing from the compressor 205 to theevaporator 230 being shunted to and through the additional expansionvalve 255 and into an outer region of a coaxial cooling tube 256. Theillustrated coaxial cooling tube incudes a central tubular section,through which fluid may flow form a tube inlet, through the centraltubular section, to the output of the coaxial cooling tube and into theexpansion valve 246. The illustrated coaxial tube includes an outersection that surrounds the central tubular section (but is fluidlyisolated from the central tubular section) such that fluid may flowthrough the additional expansion valve, into and through the outercoaxial section, and into the fluid return line. Thus, when theadditional expansion valve 255 is activated, fluid will be flowing inopposite directions through the coaxial cooling tube, such that fluidwill be flowing in one direction through the tube to the expansion valve246 and fluid will be flowing in the opposite direction from theadditional expansion valve 255 through the coaxial cooling tube to thefluid return. This flow will result in an expansion of the refrigerantflowing through this annular cavity and a cooling of the fluid beingprovided to the main expansion valve 246 (discussed above). It should benoted that this coaxial arrangement is one embodiment of the design, andadditional configurations exist with similar impact, such as atube-to-tube configuration wherein one tube contains the expandedrefrigerant leaving expansion valve 255 which is thermodynamicallyconnected to the liquid filled refrigerant line feeding expansion valve246. The operation of the additional expansion valve 255 may thus beused to cool the refrigerant entering the main expansion valve 246 (andthus the refrigerant entering the evaporator 230). By controlling thetiming, manner, and extent to which the additional expansion valve 255is operated, the extent to which the refrigerant flowing into theevaporator 230 is cooled may be controlled. One exemplary reason forthis increased control is because the cooling provided by operation ofthe additional expansion valve 255 will increase the capacity of theevaporator 230.

In certain embodiments, the timing and operation of the additionalexpansion valve 255 will depend on the operating conditions of thedispenser. For example, the evaporator 230 may be sized such that, innormal operation when a properly frozen product is within the freezingchamber, the refrigerant cooling provided by operation of the additionalexpansion valve 255 is not required. However, during conditions wherethe conditions within the freezing cylinder 2500 may benefit from anincrease in the capacity of the evaporator 230—such as during an initialcool-down of a product load within the cylinder or a refreezing of thecylinder contents after a defrost operation—the additional expansionvalve 255 may be operated as described to improve the operability of thesystem. Notably, in the arrangement of FIG. 10C, operation of theadditional expansion valve 255 does not result in an appreciablereduction of the mass flow and/or cooling effect, of the refrigerantentering the evaporator 230. During high load conditions, the increasedtemperature of the evaporated refrigerant leaving the evaporator 230 andentering the compressor 205 results in a lower density of therefrigerant, and consequently a lower total mass flow through thecircuit. Since the output from the valve 255 is fed back into therefrigerant line feeding the annular cavity of 256 and evaporating onthe surface of the liquid filled refrigerant line feeding expansionvalves 255 and 246 in one embodiment, or a tube thermodynamicallyconnected to the liquid filled refrigerant line feeding expansion valves255 and 246 in an alternative embodiment, two conditions existsimultaneously: (1) the evaporating refrigerant leaving expansion valve255 cools the liquid refrigerant flowing through the liquid filledrefrigerant line further reducing the energy state of the refrigerantentering expansion valve 246, and consequently reducing the energy stateof the refrigerant entering evaporator 230 thereby increasing thecooling effect of the refrigerant flowing through evaporator 230; and(2) cooling the refrigerant leaving the evaporator 230 and entering thecompressor 205, thereby increasing the density of the refrigerantentering the compressor resulting in an increase of the relative massflow of refrigerant in the circuit.

In still further embodiments, the activation of the additional expansionvalve 255 may be dependent on the temperature differential between thetemperature of the uncompressed refrigerant entering the compressor 205and the temperature of the compressed refrigerant exiting the compressor205, or on the temperature differential between the temperature of theuncompressed refrigerant leaving the evaporator 230 and entering thecompressor 205, or only on the temperature of the uncompressedrefrigerant leaving evaporator 230, or only on the temperature of thecompressed refrigerant exiting the compressor 205. In such embodiments,if the temperature of the compressed refrigerant entering or exiting thecompressor 205 is determined to be above a configurable threshold limit,the additional expansion valve 255 may be operated in a manner to bringthe entrance or exit temperature to within a desired range.Additionally, or alternatively, the operation of the additionalexpansion valve 255 may be based on the temperature differential betweenthe refrigerant inlet and outlet of compressor 230.

In still further embodiments, the cooling capacity of the evaporator 230can be modulated through activation of valves 245, 246, and 255 invarious sequences. For example, the hot gas bypass valve 245 can beoperated concurrent with the primary expansion valve 246 to provide an‘unloading’ effect for the evaporator. It should be noted that the hotgas bypass valve can take a variety of forms beyond that of a standardsolenoid. Some examples of which are a standard solenoid with adownstream restricting orifice, or a motorized valve.

In yet further embodiments, capacity of the refrigeration system 100 canbe modulated through the use of a variable speed compressor 205. Thecapacity of the primary refrigeration system could be controlled usingexternal sensor input and available data from the system controller tovary the speed of the compressor motor, resulting in a change in theresulting mass flow of the refrigerant flowing through the refrigerationsystem. The compressor speed, and resulting refrigerant mass flow wouldbe known, and the expansion valve 246 and second expansion or liquidinjection valve 255 could be tuned by the system controller to match theoutput of the compressor. Additionally, if the condenser fan 200 is afan configuration with multiple or variable speeds, the condenser fanspeed could be controlled to modulate condenser performance in responseto the associated changes in compressor output.

These aforementioned capacity regulating methods provide significantadvantage for the energy efficiency of the system, demand responsecapabilities, as well as in situ adjustments to the cooling needs of theequipment.

As will be appreciated, operation of the disclosed refrigeration systemto cool the interior of the refrigerated ingredient storage compartment2600 will tend to cause condensate to build up on the evaporator coils7040 (see FIG. 7C) within the refrigerated compartment. In theillustrated example, the condensate may build up on the coils to thepoint that it aggregates and drips by gravity into the condensate tray7050 positioned below the coils. Under certain conditions, it ispossible that condensate may build up and freeze on the coils. Insituations where such conditions may be encountered, the system can beconfigured to implement a coil defrost function in which the coils aredefrosted, and the frozen condensate is liquified and shed from thecoils. One exemplary approach for implementing such a coil defrostfunction is to allow for a defrost period in which—during a period oftime—the compressor for the ingredient storage compartment is notoperated such that a period is provided for the coil to defrost and anycondensate to drain from the coil. Additionally, or alternatively,combinations of discrete evaporator control can be used independently orin conjunction with the defrost period described above. A stillfurther—additional or alternative—method of defrosting would be to use adedicated heating element to warm the air around and/or passing over theevaporator to facilitate the defrosting and draining of the condensatefrom the coil.

In certain embodiments the condensate tray 7050 may be a removablestructure that may be removed and emptied by the system operator on aregular basis. Alternate embodiments are envisioned wherein an activecondensate processing system is included within the overall dispensingsystem to automatically evacuate condensate from the system. One suchalternate embodiment is shown in FIGS. 11A and 11B.

In FIG. 11A an exemplary primary condensate tray 4050 is shown whichdefines a large trough-like reservoir 4051 that may be positioned belowthe evaporator coil 4040 (or any other structures from which condensatemay drip) to collect condensate. The exemplary trough further defines anopening that extends into a condensate discharge spout 4052. Althoughnot depicted in FIG. 11A, additional condensate trays 4050, similar inconstruction to the depicted tray may be positioned at any locationwithin the system where condensate may collect.

In the example of FIG. 11A the condensate collected within the primarycondensate tray (or trays) 4050 is fed from the discharge spout (orspouts) 4052 into a main condensate collection tray 4053, which is shownin FIG. 11B. As reflected in FIG. 11B, the main condensate collectiontray 4053 is positioned on a lower surface of the dispenser and at alocation over which air sucked into the system through the vents 1015 inthe front kick-plate 1010 by the shared condenser fan 200 will flow.This passage of air will tend to cause condensate collected within themain condensate tray 4053 to evaporate and be expelled from the interiorof the system.

To further promote evaporation of condensate from the main condensatecollection tray 4053 the compressed hot-vapor discharge line from one ofthe compressors in the system (e.g., the compressor associated with theingredient storage refrigeration system) may be routed such that aportion of the lines passes through the main condensate collection tray4053. The passage of such lines through the tray 4053 will help to heatany condensate within the main condensate tray and further promoteevaporation. In one embodiment, the heating provided by the routing ofthe discharge line is such that the temperature of the fluid within themain condensate collection tray can reach 90° F.

Note that the use of the discharge line from the ingredientrefrigeration system compressor as a means for heating the condensate inthe main condensate collection tray 4053 is exemplary only. Alternatesources of heat could alternatively or additionally be used including,but not limited to: (a) the discharge line associated with the freezingcylinder refrigeration system compressor; (b) the discharge lines fromboth compressors in the system; (c) the output fluid line from theheater element 2801; and/or (d) the output of a dedicated heatingelement.

In the example of the FIGS. 11A-11B, the main condensate collection traymay have a volume that is approximately twice that of the volume of the(or one of the) primary condensate trays 4050. For example, in oneembodiment, the primary condensate tray 4050 will be sized such that itcan store approximately 14.3 cubic inches of fluid, while the maincondensate collection tray 4053 will be sized to store approximately31.3 cubic inches of fluid.

It will be appreciated that the condensate processing system describedabove may be used to process and eliminate fluids that may build upwithin the dispensing system other than the condensate falling from theevaporator 4040. For example, in embodiments where input air iscompressed in the unit, or onsite, stored in an accumulator, filteredand/or dried, fluid may be collected as part of that operation. Suchfluid may be collected at the location where the air is compressed,stored, or regulated, (e.g., the pressure regulator 2012 shown in FIGS.2A-2C) through the use of a primary collection volume and then passed tothe main condensate collection tray 4053 for processing as describedabove. The aforementioned process would constitute a ‘blow down’ processto remove the condensate built up in the compressed gas system. Oneembodiment of this ‘blow down’ process could occur through the use of amechanical float valve, which would open when sufficient volume ofcondensate formed in the collection volume such that sufficient buoyantforces were generated to lift the float and open the flow path. Thefloat would automatically re-seat when the condensate had beenevacuated. Another embodiment of the ‘blow down’ could be the use of asolenoid valve, which when activated, would allow the passage ofcondensate from the collection volume into the condensate managementsystem. This solenoid could be controlled through a variety of methods,one of which would be an automatic timer, or similar function from thesystem controller. It will be appreciated that the components comprisingthe compressed gas system, especially the accumulator 2008, and pressureregulator 2012, and any interconnecting tubing, are arranged in a mannerwhich promotes drainage through gravitational forces of any condensateformed within the system into the primary collection volume.

As generally discussed below, during operation of the described systemingredients used for the formation of a dispensed product may be mixedwith one or more pressurized gases and then the gas/ingredient mix maybe pumped into the freezing cylinder 2500 where the ingredient/gas mixwill be processed to form a food product that may be dispensed throughactivation of the dispensing assembly as described above.

FIG. 12 illustrates a side view of the exemplary dispensing system thatdepicts several of the components involved in the preparation anddispensing of food products. One of the side panels has been hidden, ashave certain components not involved in the operations under discussing.

A reflected in FIG. 13A, the faceplate 3000 and the associateddispensing system may be coupled to the freezing cylinder 2500 which islocated within an insulated cold pack assembly 1200. As described inmore detail below, components within the cold pack assembly 1200 may becoupled to an electric motor 1202 through the use of a gearbox assembly1204 and a motor mounting plate 1207.

As depicted in FIG. 12 , the cold pack assembly 1200 containing thefreezing cylinder 2500 is mounted on top of the ingredient storagerefrigeration cabinet 2600 discussed above. Although not illustrated inFIG. 12 , the fluid connection containing the ingredient/gas mix willflow from the interior of the refrigerated compartment 2600 and into andthrough an opening feeding the freezing cylinder 2500 and may bepositioned such that it extends within an insulated area of the coldpack assembly 1200. As such, and as a result of the refrigerated natureof the refrigeration cabinet, the refrigerated nature of the freezingcylinder 2500 and the chilled or frozen product within the freezingcylinder 2500, the material within this fluid connection will bemaintained at temperature levels that may be configured by an operatorduring operation of the disclosed system.

In the exemplary embodiment disclosed herein, the fluid connectionfeeding the ingredient/gas mixture into the freezing cylinder 2500 isdesigned to feed the ingredient/gas mixture through an opening locatedat the bottom portion of the freezing cylinder and at a location closerto the electric motor 1202 than to the faceplate 3000. In one exemplaryembodiment, the opening into the freezing cylinder is positioned in thebottom freezing cylinder 2500 (referenced from the top to the bottom ofthe cylinder) and in the rear one-quarter of the freezing cylinder 2500(with the rear being the end of the cylinder closest to the motor 1202).

FIG. 13A illustrates a cross section of several of the componentsdescribed in FIG. 12 . In particular, FIG. 13A depicts: a cross-sectionof a portion of the motor 1202 and, a cross section of: the gearboxassembly 1204, a motor mounting plate 1207, the freezing cylinder 2500and certain other components discussed in more detail below.

While any suitable electric motor and gearbox assembly may be used, inthe illustrated example under discussion motor 1202 takes the form of avariable speed electronically controlled motor. Such a motor may takethe form of a controlled induction motor (“CIM”); a brushless permanentmagnet motor (“BPM”); a switch reluctance motor (“SRM”), or any othermotor that can be controlled to rotate at multiple speeds and/or over avariable speed range.

In the illustrated exemplary embodiment of FIGS. 13A-13D, the outputfrom the motor 1202 is coupled to the input of a gearbox assembly 1204.The gearbox assembly 1204 may take any suitable form and may, in someexamples, be integrally provided with the electric motor 1202. Asgenerally reflected in FIGS. 13A-13D, a motor mounting plate 1207 iscoupled to the face of the gearbox assembly 1204, and a floatingalignment plate 1216 positioned such that it engages the motor mountingplate 1207. A motor shaft 1208 extends from the gearbox assembly,through the motor mounting plate 1207, through the floating alignmentplate 1216, and into a recess that is formed within a coupling shaft1210. An O-ring gland element 1212 surrounds the coupling shaft 1210.The O-ring-gland element 1212 includes a first region having a firstgeneral cross-sectional width that is positioned within the freezingcylinder 2500 and a second region having a second generallycross-sectional width extending through a rear opening in the freezingcylinder 2500 and into a recess formed within the floating alignmentplate 1216. In the example under discussion, the cross-sectional widthof the first region is greater than the cross-sectional width of thesecond region. In the example of FIGS. 13A-13D, the floating alignmentplate 1216 is bolted, on a first side, to mounting structure associatedwith the freezing cylinder 2500 and, on a second side, to the motormounting plate 1207. In the illustrated example a gasket element 1206 ispositioned between the floating alignment plate 1216 and the componentsforming the exterior portions of the cold pack assembly 1200 to helpthermally isolate the interior of the cold pack assembly 1200 from theother portions of the apparatus and from the outside environment.

As best shown in FIGS. 13A and 13D, an output from the coupling shaftcouples with a recess in an auger coupling element 1218 that, in turn,is coupled to a rear receiving recess within an optional/removable augercore element 1220 of an auger assembly. The core element 1220 of theauger assembly is a generally cylindrically shaped element that extendsalong substantially the entire length of the freezing cylinder 2500.Auger prop elements 1222 (only portions of which are shown in FIG. 13A)extend from the auger core and may be coupled to one or more bars (notshown in FIG. 13A) that extend from a rear auger plate 1226.

FIGS. 14A and 14B further reflects details of the auger assembly. Asshown in FIG. 14A, the auger core extends from the auger couplingelement 1218, along substantially the entire length of the auger, to andthrough an opening defined at the end of the auger assembly that—inuse—will be closest to the faceplate. As reflected in FIG. 14A, thefaceplate end of the auger core 1220 defines a feature that may bereceived within, and engage a corresponding recess formed in thefaceplate 3000 (such as the recess 3009 of FIG. 3B). In suchembodiments, the manner in which the auger core assembly 1220 engageswith the faceplate recess and the auger coupling element may be suchthat the auger core rotates along with the auger assembly whenever theauger assembly is rotated. Alternatively, the manner in which the augercore assembly 1220 engages with the faceplate recess and the augercoupling element may be such that the engagement of the auger coreelement 1220 with the faceplate recess will prevent rotation of theauger core assembly 1220 while the engagement between the auger coreelement 1220 with the auger coupling element 1218 will permit the augercore element to rotate with respect to the remaining elements of theauger assembly.

As further reflected in FIG. 14A three bars 1240 extend from the rearauger plate 1226 along substantially the entire length of the augerassembly. In the illustrated example, three flat blades 1250 (which maybe spring biased and allowed to flex radially) are positioned onextensions from the auger bars 1240 and may be used to scrape the innersurface of the freezing cylinder 2500 during operation. As depicted inFIG. 14A, the bars 1240 terminate with attachments to an auger propelement 1222 that is designed and shaped to move product within the areaencompassed by the prop element towards the faceplate 3000.

As will be apparent from FIG. 14A, the entire auger assembly may beeasily separated from the remainder of the dispenser system when thefaceplate is removed by simply pulling the auger assembly out throughthe open end of the freezing cylinder 2500. As will also be apparentfrom FIG. 14A, the auger core element 1220 may be easily separated fromthe remainder of the auger assembly by pulling it out of, and away from,the auger coupling element 1218. It will also be apparent from FIG. 14A,the flat blades 1250 may be easily separated from the remainder of theauger assembly. The flat blades 1250 also contain 2 scraping edges, onlyone of which is active in a given orientation, and indicators fororientation of the blade with respect to rotation of the auger assembly.It may be appreciated that these features extend the service life of theblades.

As described above, use of the auger core element 1220 is optional. FIG.14B illustrates the auger assembly with the core element 1220 removed.As will be appreciated, when the auger core element 1220 is used, theshape of the auger core may be configured and optimized to match thedesired characteristics for the product to be dispensed from thedispenser. Thus, for example, the auger core element configuration usedfor a freezing cylinder 2500 intended to dispense soft-serve ice creammay differ in construction from an auger core element intended for usewith a freezing cylinder intended to dispense a shake or a smoothie.

As reflected in FIGS. 13A and 13B a rear seal drip tray 1228 may beprovided to catch content flowing from the freezing cylinder 2500 in theevent of an unexpected failure of the rear seal. In someembodiments—such as the one depicted in FIG. 13B—the rear seal drip tray1228 may include a sidewall with an opening such that product will spillthrough the opening in the event of a product buildup within the rearseal drip tray 1228. In such embodiments, the opening may be positionedsuch that any outflow of product through the opening will be readilyobservable by a user or operator of the dispenser. For example, theopening may be positioned on a side of the dispenser in the manner shownin FIG. 1C for element 1085.

Referring back to FIG. 10A, one exemplary location for the port 1230through which the product ingredient/gas mixture (and/orcleaning/sanitizing solution) is pumped into the freezing cylinder isshown. While such a port may be used to introduce a productingredient/gas mixture (or cleaning/sanitizing fluid) into the freezingcylinder at any desired location, in one exemplary embodiment, theintroduction of the product ingredient/gas mixture (during a productformation and dispense) and the introduction of the cleaning/sanitizingsolution (during a self-cleaning operation) occurs at a location behindthe auger mounting plate 1226. One such location is identified as region1231 in FIG. 13A.

Referring again to FIG. 13A, it will be appreciated that the combinationof the depicted variable speed electric motor 1202 with an augerassembly (for example the auger assembly of FIG. 14A) produces a productformation system that has a high degree of variability. Not only doesthe described example permit easy and efficient modification of theauger assembly to match a desired product or certain desired productcharacteristics, the use of variable speed electronic motor 1202 permitsthe rotational speed of the motor to be varied during the operation ofthe dispenser, and permits the direction of rotation to be reversed.Thus, for example, during a self-cleaning operation, the motor 1202 maybe operated at rotational speeds that are higher—and in some instancesmore than 25% higher—than the average rotational speed used duringproduct formation and dispense operations. The direction of rotation mayalso be changed between counterclockwise and clockwise directions duringcertain operations. Additionally, and/or alternatively, the rotationalspeed of the motor 1202 may be varied depending on the state of theproduct within the freezing cylinder 2500. For example, during aninitial pull-down and/or refreezing operations, the motor 1202 may beoperated at a rotational speed that is lower than—and potentially morethan 15% lower than—the rotational speed used during periods where theproduct within the freezing cylinder 2500 is frozen and ready to bedispensed. The use of a slower rotational speed in such circumstancesmay result in a change in the freezing characteristics of the productwithin the freezing cylinder and may have many other uses to thoseskilled in the art and in possession of this disclosure.

Still further, the use of a variable speed drive system permits themotor 1202 to be driven at a very low rotational rate during anyoperation where the motor is rotated, and the rotor current is detectedto determine the freeze state of the product within the cylinder. Duringsuch freeze-check operations the use of a low rotational speed bothsaves energy (and thus energy costs) by using a low rotational speed forsuch operations and avoids the introduction of unnecessary energy (andthe resultant heat) that would result from a high-RPM freeze checkoperation. Further, depending on the nature of the product within thecylinder, the use of lower rotational speeds can reduce productbreakdown and/or maintain desired product consistency andcharacteristics.

Still further, during intervals where the interior of the cylinder 2500is being defrosted, the motor 1202 may be run at a rotational speed thatis higher than—and potentially as much as 30% higher than—the rotationalspeed at which the dispenser normally operates during a product dispenseoperation. The use of such a high rotational speed helps to improvemixing while defrosting and helps prevent frozen product from clingingaround the center of the auger and not melting, thus decreasing the timerequired to complete the defrost application.

And further, the use of a variable speed motor allows the discloseddispenser to more effectively freeze down, maintain, and dispensedifferent products without having to make any meaningful mechanicaladjustments within the system. As will be appreciated, differentproducts require different auger rotational speeds during productformation and dispense operations for optimal performance. For example,shakes and smoothies require faster RPMs than soft serve for optimumproduct quality. The use of the disclosed variable speed motor 1202 (andan associated motor drive) allows the motor speed during variousoperating conditions to be easily and optionally configured to a varietyof different products.

FIGS. 13C and 13D (in conjunction with FIG. 13A) illustrate detailsconcerning the rear seal assembly used in the disclosed embodiments.

As reflected in certain of the figures, the gearbox assembly 1204terminates in a relatively flat face from which a rotating shaft 1208extends. As best reflected in FIG. 13C, an alignment feature 1209extends from the face of the gearbox assembly 1204 about the rotatingshaft 1208. In general, the alignment feature is such that an elementpositioned about the alignment feature 1209 will be concentricallyaligned with the rotating shaft 1208.

A floating alignment plate 1216 is provided that defines a passage thatpasses through the entirety of the plate. In the example of FIG. 13C thealignment plate includes a first set of openings that may be used toreceive a plurality of connecting elements (e.g., bolts) that can affixone side of the alignment plate (the left side in FIGS. 13A and 13C)directly to the freezing cylinder 2500. In one of many possibleembodiments the bolts used to connect the floating alignment plate 1206may be configured to be integrally formed with, and extend from, thefreezing cylinder. The alignment plate may be formed from a lowthermally conductive material—such as low conductivity thermoplastic—tominimize any transfer of heat from the motor assembly to the freeingcylinder 2500.

In the examples of FIGS. 13A and 13C, the floating alignment plate 1216includes a recess that may be configured to receive the alignmentfeature 1209 that extends from the gearbox 1204. The floating alignmentplate 1206 further includes a second set of openings that may be used toreceive a second plurality of connecting elements (e.g., bolts or otherthreadable members) that may be used to affix a second side of thealignment plate (the right side in FIGS. 13B and 13D) to the motormounting plate 1207.

As best shown in FIG. 13B, the coupling of the floating alignment plate1216 with the exposed face of the gearbox assembly 1204 may—because ofthe receipt of the alignment feature 1209 within the floating alignmentplate 1216—ensure concentric and axial alignment of the plate 1216 withthe rotating shaft 1208 extending from the gearbox 1204. Further,because the floating alignment plate 1216 is directly attached to thefreezing cylinder 2500, the floating alignment plate 1206 will beaxially and concentrically aligned with the freezing cylinder 2500 (andin particular the opening passing through the end of the freezingcylinder). Accordingly, because the disclosed arrangement ensures properalignment between the floating alignment plate 1216 and the freezingcylinder 2500 on one side of the plate, and proper alignment of thealignment plate 1216 and the rotating shaft 1208 from the gearbox 1204,the illustrated arrangement further ensures proper axial and concentricalignment between the rear opening in the freezing cylinder 2500 and therotating shaft 1208 extending from the gearbox 1204.

As shown in FIGS. 13A and 13C—and as generally described above—a gasket1206 may be positioned between the floating alignment plate 1216 (or anyother components within the system) and the freezing cylinder 2500 (or afeature of the cold pack assembly) to minimize thermal loss from theinterior of the faceplate.

Referring back to FIG. 13D, in the specific illustrated embodiment, itmay be seen that the inner surface of the opening in the rear of thefreezing cylinder has configurable features (e.g., ridges) that may beadapted to receive mating features in a first portion of the O-ringgasket element 1212 and that the floating alignment plate 1216 alsodefines an opening having an inner surface defining features adapted toengage with mating features associated with a second portion of theO-ring gasket element 1212. It will be appreciated that the constructdepicted in FIG. 13D is exemplary and optional and that the function ofelement 1212 could be provided through alternative structures. Forexample, the same or a similar feature could be included in an elementcomprising the freezing cylinder 2500.

As also reflected in FIG. 13A, when assembled, the coupling shaft 1210is positioned such that it extends from within the freezing cylinder2500, through the opening 1300 in the rear of the cylinder, through theinterior of the O-ring gasket element 1212, and through the floatingalignment plate 1216 until it engages within the rotating shaft 1208extending from the gearbox 1204. In one embodiment, the engagementbetween the O-ring gasket element 1212 and the inner surface of theopening 1300 through the rear of the freezing cylinder 2500 (and/or theengagement between the O-ring gasket element 1212 and the inner surfaceof the floating alignment plate 1216) when the coupling shaft 1220 ispositioned as shown is such that rotation of the O-ring gasket element1212 is prevented. This can be accomplished, for example, by having theO-ring gasket element 1212 define features that are received withineither the rear wall of the freezing cylinder and/or or a portion of thefloating alignment plate that will inhibit rotational movement of thegasket element (and/or vice versa, e.g., features associated with therear wall of the freezing chamber and/or the floating alignment platethat engage with the gasket element 1212. The non-rotation of the O-ringelement 1212, ensures that the only relative rotation between elementsof the illustrated rear sealing structure is between the rotatingcoupling shaft 1212 and 1210 and the resilient O-ring sealing gasket1212, such that any wear resulting from rotation will occur with respectto these elements which are easily replaceable and accessible from thefront portion of the system. In other words, because the O-ring sealinggasket 1212 and/or the coupling shaft 1210 can both be accessed throughthe open end of the freezing cylinder 2500 (without having todisassemble significant elements of the system), replacement of suchelements is simplified.

It will also be appreciated from an inspection of FIGS. 13A, 13C and 13Dthat the coupling shaft element may (with the faceplate and augerassembly removed) be easily removed from the front of the machine bysimply pulling the coupling shaft out the open front of the freezingcylinder. The same may be true for the removal of the resilient O-ringstructure. Furthermore, as will be appreciated by those in receipt ofthis disclosure, replacement or initial installation of the resilientO-ring structure and the coupling shaft will be straightforward and maybe accomplished easily through front-access of the machine opening.

It will be appreciated that the rear seal design discussed above resultsprimarily from radial compression of the resilient O-ring structure (inparticular radial compression on the outer diameter of the O-ringstructure) and that there is no, to minimal, reliance on axiallycompressive forces for the establishment of the rear seal. This use of aradially compressive seal helps to minimize component wear.

It will further be appreciated that, to the extent that there is anyleakage path from the interior of the freezing cylinder to the exterior,that leak path will be around or through the resilient O-ring structureand that there are no leakage paths through any rotating, non-resilient,bearing structures.

It may be noted from an inspection of FIG. 13C that there is nocontinuous face seal established between the surface of the gear box1204 and the mounting plate 1207 and that the floating alignment plate1216 is configured such that there is an open recess surrounding theopening through which the rotating shaft 1208 extends from the floatingalignment plate 1216. This configuration is significant because itensures that the region surrounding the opening through which therotating shaft extends from the gearbox is maintained at atmosphericpressure (and there is no potential for pressure build up). Maintainingthat region at atmospheric pressure ensures that no unwanted materialsare forced into the gearbox or motor assemblies.

FIGS. 13E-1 and 13E-2 illustrate an alternative rear seal assembly. Inthe alternative illustrated example, the rear seal is formed from a dualO-ring structure that includes a first O-Ring element 1311 that fitswithin a region of the freezing cylinder 2500 and a second O-Ringelement 1312 that fits within a recess within the first O-Ring element1311. In the illustrated example of FIGS. 13E-1 and 13E-2 the firstO-Ring element 1311 is position such that it includes horizontal regionsabutting edges of the freezing cylinder 2500 and vertical rear regionsabutting the floating alignment plate 1216. In the same example, thesecond O-Ring element 1312 is positioned such that it includes regionsabutting the first O-Ring element 1311 and portions of the freezingbarrel 2500.

As will be appreciated, one benefit of the motor mounting structuredescribed above is that that there is general alignment of the motor (orgearbox) output shaft and the auger assembly within the freezingcylinder. As such, it is possible to position both the cold-packcontaining the freezing cylinder and the motor 1202 and the gearboxassembly 1204 above a horizontal plane that passes above the ingredientrefrigeration unit. This promotes an efficient usage of space andeliminates the need for pullies or belt systems. Still further, thearrangement described herein is one where a longitudinal axis extendingthrough the motor output shaft is passes through both the interior ofthe freezing cylinder and the faceplate. Again, this arrangementpromotes efficient use of space.

Other and further embodiments utilizing one or more aspects of theinventions described above can be devised without departing from thespirit of Applicant's invention. Further, the various methods andembodiments of the methods of manufacture and assembly of the system, aswell as location specifications, can be included in combination witheach other to produce variations of the disclosed methods andembodiments. Discussion of singular elements can include plural elementsand vice-versa.

The order of steps can occur in a variety of sequences unless otherwisespecifically limited. The various steps described herein can be combinedwith other steps, interlineated with the stated steps, and/or split intomultiple steps. Similarly, elements have been described functionally andcan be embodied as separate components or can be combined intocomponents having multiple functions.

The inventions have been described in the context of preferred and otherembodiments and not every embodiment of the invention has beendescribed. Obvious modifications and alterations to the describedembodiments are available to those of ordinary skill in the art. Thedisclosed and undisclosed embodiments are not intended to limit orrestrict the scope or applicability of the invention conceived of by theApplicants, but rather, in conformity with the patent laws, Applicantsintend to protect fully all such modifications and improvements thatcome within the scope or range of equivalent of the following claims.

What is claimed is:
 1. A self-cleaning frozen food processing anddispensing apparatus comprising: a cabinet comprising a frame structureand a plurality of panel members; a freezing cylinder located within thecabinet, the freezing cylinder having an inlet; a first evaporatorpositioned to cool the freezing cylinder; a faceplate coupled to an openend of the freezing cylinder, the faceplate defining: a dispense borepassing generally vertically through the faceplate and a bypass passagehaving a first end opening; a valve stem positioned at least partiallywithin the dispense bore, the valve stem including a sealing surface forcreating a seal with a portion of the dispense bore; and a valve stemactuator coupled to the valve stem, the valve stem actuator beingconfigured to move the valve stem from a first position where dispensingof a food product from within the freezing cylinder is permitted to asecond position where the seal between the valve stem and the dispensebore precludes dispensing of the food product; wherein the bypasspassage is positioned such that, when the valve stem is in the firstposition, no fluid path exists between interior of the freezing cylinderand the first end of the bypass passage; a first compressor positionedwithin the frame structure at a location below the freezing cylinder,the first compressor being coupled to provide refrigeration fluid to thefirst evaporator; a refrigerated ingredient storage compartment, therefrigerated ingredient storage compartment being positioned within thecabinet at a location below the freezing cylinder and above the firstcompressor; a cleaning fluid tank located within the cabinet, thecleaning fluid tank having an outlet; a self-cleaning receiver portfluidly coupled to the outlet of the cleaning fluid tank; a fluid pumplocated within the refrigerated ingredient storage compartment, thefluid pump the having an inlet and an outlet, the inlet of the fluidpump being fluidly coupled to a pump connection element that may beremovably coupled to the self-cleaning receiver port, and the outlet ofthe fluid pump being fluidly coupled to the inlet of the freezingcylinder, wherein, when the pump connection element is removably coupledto the self-cleaning receiver port, activation of the fluid pump willresult in the pumping of cleaning fluid from the cleaning fluid tankinto the food dispensing cylinder without the use of any interveningpumping elements.
 2. The apparats of claim 1 further comprising a secondcompressor and a second evaporator, wherein the second compressor ispositioned within the frame structure below the refrigerated ingredientstorage compartment and wherein the second compressor and the secondevaporator are adapted to cool the interior of the refrigeratedingredient storage compartment.
 3. The apparatus of claim 1 furthercomprising: a hinged insulted door coupled to the frame structure, thehinged door being movable to permit access to the interior of therefrigerated ingredient storage compartment; and a drip tray coupled tothe hinge door, at least a portion of the drip tray being positionedgenerally below the dispense bore.
 4. The apparatus of claim 1 furthercomprising a container positioned within the refrigerated ingredientstorage compartment for storage of a food product ingredient, thecontainer comprising a connection port configured to be connected to theremovable pump connection element such that a fluid connection may bemade between the interior of the container and the pump connectingelement.
 5. The apparatus of claim 4 wherein the container comprises arigid structure.
 6. The apparatus of claim 4 wherein the containercomprises a collapsible bag.
 7. The apparatus of claim 1 wherein thepump connection element is removably connected to the self-cleaningreceiver port at a location within the refrigerated ingredient storagecompartment.
 8. A food product processing and dispensing apparatuscomprising: a frame; a plurality of panel members coupled to the frame aproduct chamber positioned within the frame, the product chamber havingan inlet; a faceplate coupled to the product chamber, the faceplatedefining a dispense bore passing generally vertically through thefaceplate and a bypass passage having a first end opening, a portion ofthe faceplate being adapted to be coupled to a blocking cap in such thatthe blocking cap, when coupled to the faceplate, blocks the dispensingof product when the blocking cap is coupled to the faceplate; a movablevalve element positioned at least partially within the dispense bore,the movable valve stem including a sealing surface for creating a sealwith an interior portion of the dispense bore; and a valve actuatorcoupled to the valve element, the valve actuator being configured tomove the valve element from a first position to permit dispensing of afood product from within the product chamber to a second position wherethe seal between the valve element and the interior of the dispense boreprecludes dispensing of the food product; wherein the bypass passage ispositioned such that, when the valve stem is in the second position, andthe blocking cap is coupled to the faceplate, a fluid path existsbetween the interior of the product cylinder and the first end of thebypass passage; a cleaning fluid tank having an outlet; a fluid pumphaving an inlet and an outlet, the outlet of the fluid pump beingfluidly coupled to the inlet of product chamber and the inlet of thefluid pump being fluidly coupled to a connection element that may beremovably coupled to one of either: a self-cleaning receiver port thatmay be fluidly coupled to the cleaning fluid tank such that activationof the fluid pump will result in creation of a negative pressure causingthe introduction of cleaning fluid from the cleaning fluid storagereservoir into the product cylinder; or the outlet of a source of a foodingredient such that when the connection element is removably coupled tothe outlet of a source of food ingredient, activation of the pump willresult in the pumping of a food ingredient into the product chamber. 9.The food processing and dispensing apparatus of claim 8 wherein theproduct chamber comprises a cylinder associated with a coolingevaporator.
 10. The food processing and dispensing apparatus of claim 8wherein the fluid pump is a peristaltic pump.
 11. The food processingand dispensing apparatus of claim 8 further comprising a pressure blockhaving a fluid inlet coupled to the outlet of the pump, a gas inletcoupled to a source of pressurized gas, an internal junction passagefluidly coupled to the gas inlet and the fluid inlet, and an outletfluidly coupled to the passage, wherein the outlet of the pressure blockis fluidly coupled to the inlet of the product chamber.
 12. The foodprocessing and dispensing apparatus of claim 11 further comprising apressure sensor positioned to provide a signal corresponding to thepressure within the junction passage.
 13. The food processing anddispensing apparatus of claim 8 further comprising a pneumaticallyactuated vent relief valve positioned within the faceplate, wherein thevent relief valve may be actuated to release product or gas from withinthe product chamber.
 14. The food processing and dispensing apparatus ofclaim 13, wherein the faceplate further comprises a vent flush bore,wherein at least a portion of the vent relief valve is positioned withinthe vent flush bore, and wherein the apparatus further comprises a ventcleaning valve having an input fluidly coupled to a source of cleaningfluid and an output fluidly coupled to the vent flush bore, wherein thevent cleaning valve may be actuated to cause cleaning fluid to flow intothe vent flush bore and across at least a portion of the vent reliefvalve positioned within the vent flush bore.
 15. A food processingapparatus comprising: a cylinder, the cylinder having an inlet forreceiving a food ingredient; a faceplate coupled to the cylinder, thefaceplate defining a dispense bore and a bypass passage having a firstopen end; a blocking cap coupled to the faceplate to block thedispensing of product from within the cylinder; and a pump having aninlet and an outlet, the inlet of pump being fluidly coupled to aconnection element that may be removably coupled to a source of cleaningfluid; wherein, when the connection element is removably coupled to thesource of cleaning fluid, activation of the pump will result in thepumping of cleaning fluid into the food dispensing cylinder, though thecylinder into the blocking cap, and through the blocking cap into thebypass passage.
 16. The food processing apparatus of claim 15 whereinthe cylinder is a freezing cylinder.
 17. The food processing apparatusof claim 15 wherein the pump is a positive displacement pump.
 18. Thefood processing apparatus of claim 15 wherein the source of cleaningfluid is in form of a tank.
 19. The food processing apparatus of claim15 wherein the faceplate includes a pneumatically operated dispensevalve.
 20. The food processing apparatus of claim 15 wherein thefaceplate includes a dispense valve actuated by an electric motor.